This document summarizes a case study conducted at Binny Food Industries, a leading ice cream manufacturer in Nepal. The key aspects covered in the case study include: 1) An overview of Binny Food Industries and their ice cream production process, including main ingredients, popular flavors, and production capacity. 2) A description of the basic ice cream manufacturing process, including blending, pasteurization, homogenization, aging, freezing, packaging, and hardening. 3) Recommendations to upgrade systems for wastewater treatment, steam generation, and automating the packaging process.

1. TRIBHUVAN UNIVERSITY
INSTITUTE OF ENGINEERING
Kathmandu Engineering College
Department of Electronics and Computer Engineering
Report On
Instrumentation-II Case Study
Visit Undertaken At
Binny Food Industries (Quality Ice Cream)
Bhainsepati, Lalitpur, Nepal
Submitted By
Ashok Kumar Bhattarai (BCT 67013)
Binaya Ghimire (BCT 67024)
Dhiraj Bashyal (BCT 67026)
Kathmandu, Nepal
2069

2. i
ACKNOWLEDGEMENT
Learning is not only based on books and text related activities. Especially, in engineering,
where innovation and technical knowledge are appreciated, learning by practical
appliances are more fruitful than learning in isolated surrounding. It exposes one to real
time working environment. Our learning process was made easier by various
personalities. With the effort of various teaching and non-teaching staffs, our case study
was successful, so we express them heart full acknowledgement. Thus we consider it as
our privilege to express through the pages of this study a few words of gratitude &
respect to all those personalities who made this task successful beside their valuable time.
We are thankful to all the staffs of Binny Food Industries (Quality Ice Cream) for their
co-operation and helping us in knowing the process of ice cream production. We are also
thankful to all the staffs for their kindness and the friendly behavior. We record our
grateful thanks to for helping us in report preparation. We are particularly grateful for Er.
Keshab Thapa our subject teacher for motivating and suggesting us for completion of
this case study. Also we would like to place grateful thanks to Department of Computer
and Electronics Engineering, of Kathmandu Engineering College for accepting our
request, Third Year Coordinator Er. Sudeep Shakya and Head of Department Er
Manish Aryal their immense support during our case study.

3. ii
TABLE OF CONTENTS
Acknowledgment………………………….………………… .. i
Table of Contents……………………………….…………… ..ii
1. Introduction……………………….........................................1
1.1 About Organization…………………………………….2
1.2 Main Ingredients for Ice Cream………………………..2
1.3 Productions…………………………………………….2
2. Ice Cream Manufacturing Process………………………….2
2.1 Block Diagram………………………………………...3
2.2 Process Flow for Ice Manufacture…………………….3
3. Recommendation of the system…………………………….7
3.1 For packaging of ice cream……………………………8
4. Discussion and Conclusion…………………………………10
5. Photo Gallery……………………………………………….11
6. References……………………………………………….....13

4. Case Study on Ice Cream Production
1
1. INTRODUCTION
1.1 About Organization
In Nepal, number of ice-cream manufacturing company is increasing day by day but
productions of quality ice-creams are declining. In the huge competition in the market,
Binny food industries Pvt. Ltd located at Bhainsepati (Sainbu) Lalitpur, Nepal; is one of
the fast growing and well established Ice Cream Company of Amatya Group whose
market brand name is “Kwality Ice-Cream”. It is working in the field of producing Ice-
Cream from 17 years. It is a pioneer ice cream company in Nepal. In 2043 B.S the
Kwality Ice Cream (India) on their diversification plan looked the Nepalese market and
found it to be an untapped feasible area. Amatya group was the first to follow the
proposal .In 2046 B.S, Amatya Group under the name of Everest ice-cream Ltd started
their ice-cream manufacturing unit under collaboration with Kwality Ice-Cream (India),
the EIC (PVT) Ltd was situated at Koteswor. But the same company is now situated in
Bhainsepati (Sainbu) Lalitpur under the name of Binny food industries since 2061B.S.
The production of ice-cream is operating on two shifts of 8 hours with the capacity of
1000 liters per day. It uses semi-automatic machine and equipment for production of ice-
cream. The main markets of the ice cream company are Birgunj, Nepalgunj, Pokhara,
Janakpur and Biratnagar except Kathmandu. The company is established with an
objective of manufacturing high quality ice-cream in the company. Beside this, another
major objective is to provide the satisfaction to consumer by marking the high quality
product at reasonable cost and develop market. The company is providing employment to
more number of people .The total number of staffs in the company is 40. Among them
15 are in production unit, 3 in account unit, 2 in administration unit, 4 are drivers, 4 are in
dispatch(supply) unit, one manager, one mechanical engineer is to be hired if needed.

5. Case Study on Ice Cream Production
2
1.2 Main ingredients for Ice-Cream
Binny Food Industries Pvt. Ltd purchase raw materials from the local and international
market. Sugar, milk, creams, etc. is been purchased from national and some other
chemical are imported from outside the country. Most of the chemical are imported from
India. Some other components like color essence are from foreign country.
1.3 Production
Binny Food Industries has produced different types of ice cream according to its
customers need. Such flavors are Vanilla, Strawberry, Chocolate, Butter Scotch,
Kesarpista, Choco-Bar, Strawberry bar, Pineapple Bar, Orange bar, Lichhi Bar etc.
2. ICE CREAM MANUFACTURING PROCESS
The basic steps in the manufacturing of ice cream are generally as follows:
• Blending of the mix ingredients
• Pasteurization
• Homogenization
• Aging the mix
• Freezing
• Packaging
• Hardening

6. Case Study on Ice Cream Production
3
2.1 BLOCK DIAGRAM
Fig 2.1: Block Diagram for production of Ice Cream
2.2 Process flow for Ice Cream manufacture
a) Blending
First the ingredients are selected based on the desired formulation and the calculation of
the recipe from the formulation and the ingredients chosen, and then the ingredients are
weighed and blended together to produce what is known as the "ice cream mix".
Blending requires rapid agitation to incorporate powders, and often high speed blenders
are used.

7. Case Study on Ice Cream Production
4
b) Batch Pasteurization
Pasteurization is the biological control point in the system, designed for the destruction of
pathogenic bacteria. In addition to this very important function, pasteurization also
reduces the number of spoilage organisms such as psychrotrophs, and helps to hydrate
some of the components (proteins, stabilizers).The mixture is kept for 2-3 hours
maintaining the temperature of 69° C to80° C to satisfy legal requirements for
pasteurization, necessary for the destruction of pathogenic bacteria. Various time
temperature combinations can be used. The heat treatment must be severe enough to
ensure destruction of pathogens and to reduce the bacterial count to a maximum of
100,000 per gram. Regeneration is lost and mix entering the cooling section is still quite
warm.
c) Plate Chiller
The main function of plate chiller is to homogenized the mixture after pasteurization
 Homogenization
The mix is also homogenized which forms the fat emulsion by breaking down or
reducing the size of the fat globules found in milk or cream to less than 1 µ m. Two stage
homogenization is usually preferred for ice cream mix. Clumping or clustering of the fat
is reduced thereby producing a thinner, more rapidly whipped mix. Melt-down is also
improved. Homogenization provides the following functions in ice cream manufacture:
• Reduces size of fat globules
• Increases surface area
• Forms membrane
• Makes possible the use of butter, frozen cream, etc.

8. Case Study on Ice Cream Production
5
By helping to form the fat structure, it also has the following indirect effects:
• Makes a smoother ice cream
• Gives a greater apparent richness and palatability
• Better air stability
• Increases resistance to melting
Homogenization of the mix should take place at the pasteurizing temperature. The high
temperature produces more efficient breaking up of the fat globules at any given pressure
and also reduces fat clumping and the tendency to thick, heavy bodied mixes. The higher
the fat and total solids in the mix, the lower the pressure should be. A pressure of 2000 -
2500 psi should be for ice cream mix. Clumping or clustering of the fat is reduced
thereby producing a thinner, more rapidly whipped mix. Melt-down is also improved.
 Ageing
The mix is then aged for at least four hours and usually overnight. This allows time for
the fat to cool down and crystallize, and for the proteins and polysaccharides to fully
hydrate. Aging provides the following functions:
• Improves whipping qualities of mix and body and texture of ice cream
.It does so by:
• Providing time for fat crystallization, so the fat can partially coalesce;
• Allowing time for full protein and stabilizer hydration and a resulting slight viscosity
increase
• Allowing time for membrane rearrangement and protein/emulsifier interaction, as
emulsifiers displace proteins from the fat globule surface, which allows for a reduction
in stabilization of the fat globules and enhanced partial coalescence?

9. Case Study on Ice Cream Production
6
Ageing is performed in insulated or refrigerated storage tanks, silos, etc. Mix temperature
should be maintained as low as possible without freezing, at or below 4° C. An aging
time of overnight is likely to give best results under average plant conditions.
 Freezing and Hardening
The mix is drawn into a flavor tank where any liquid flavors, fruit purees, or colors are
added. The mix then enters the dynamic freezing process which both freezes a portion of
the water and whips air into the frozen mix. The "barrel" freezer is a scraped-surface,
tubular heat exchanger, which is jacketed with a boiling refrigerant such as ammonia or
Freon. Mix is pumped through this freezer and is drawn off the other end in a matter of
30 seconds, (or 10 to 15 minutes in the case of batch freezers) with about 50% of its
water frozen. There are rotating blades inside the barrel that keep the ice scraped off the
surface of the freezer and also dashers inside the machine which help to whip the mix and
incorporate air.
Ice cream contains a considerable quantity of air, up to half of its volume. This gives the
product its characteristic lightness. Without air, ice cream would be similar to a frozen ice
cube. The air content is termed its overrun, which can be calculated mathematically.
As the ice cream is drawn with about half of its water frozen, particulate matter such as
fruits, nuts, candy, cookies, or whatever you like, is added to the semi-frozen slurry
which has a consistency similar to “soft-serve ice cream”. In fact, almost the only thing
which differentiates hard frozen ice cream from soft-serve, is the fact that soft serve is
drawn into cones at this point in the process rather than into packages for subsequent
hardening.
 Hardening (cold room)
After the particulates have been added, the ice cream is packaged and is placed into a
blast freezer at -30° to -40° C where most of the remainder of the water is frozen. Below
about -25° C, ice cream is stable for indefinite periods without danger of ice crystal
growth; however, above this temperature, ice crystal growth is possible and the rate of

10. Case Study on Ice Cream Production
7
crystal growth is dependent upon the temperature of storage. This limits the shelf life of
the ice cream.
Hardening involves static (still, quiescent) freezing of the packaged products in blast
freezers. Freezing rate must still be rapid, so freezing techniques involve low temperature
(-40° C) with either enhanced convection (freezing tunnels with forced air fans) or
enhanced conduction (plate freezers).
Some other terms:
 Lolly tank
Lolly tank is used for manufacturing choc-bar. Calcium chloride (Cacl) is used for
freezing in lolly tank.
 Butter Room:
The butter room is used for storing the butter at the temperature around 4°C. The capacity
of butter room is 1000 Kg.
3. Recommendation for the System (Upgrading):
 Wastewater
A wastewater system was designed to process approximately 1,630 m3 per day of wastewater
from the ice cream manufacturing facility. The proposed design processes the wastewater and
purifies it again for cleaning at a cost of $1.58/m3. Figure 3 gives the block flow diagram for the
process. The wastewater from the process first passes through the screener to remove all solids
larger than 2 mm, and then passes on to the equalization tank. Here, the water is slowly released
to the primary clarifier, where organic material is removed to lower the biological oxygen
demand (BOD) to 525 mg/L before the water goes to the activated sludge basin. In the activated
sludge basin, the water is aerated, and, through biological activity, the BOD is reduced by 95% to
25 mg/L. In the secondary clarifiers, the biomass is removed and a fraction is recycled the
matter from the primary clarifier, where it is desiccated and turned into compost. After the water

11. Case Study on Ice Cream Production
8
leaves the secondary clarifiers, it passes through a reverse osmosis step to prepare store the
purified water for the next cleaning shift.
 Steam Generation
In the proposed facility, low-pressure steam will be used for pasteurization, jacketed heating of
the mixing equipment, and to heat water for equipment cleaning. Figure 4 is a block flow diagram
of the steam generation and users. Here the different components are on different boxes and are
connected to the batch pasteurization in which the temperature is maintained at 75°C. The entire
tank is controlled by the microcontroller and on and off time for each tank is fixed dependent on
the quantity of component needed for the mixture. There is valve on each of the tank mouth
which is on and off which are controlled by the microcontroller.
Fig:3.1 Block Diagram for Recommended System
3.1 For packaging of the ice cream
The system used in manufacturing the ice cream is both manual and automatic. Up to
continuous freezing the process is same worldwide and the system is automatic i.e. there
is no manual work but the packaging process is totally manual which is time consuming.
So the system upgrade is only in the packing of the ice cream. The major component of
the block diagram is the microcontroller which is used to control all other block of the
system. It controls all the other part of the system. It is the heart of the system. Every

12. Case Study on Ice Cream Production
9
element of the system is driven by it. 8255 is the programmable peripheral interface from
which the different system part is connected. Time is set for the belt to move and to stop
in which fixed number of cup are placed. There is use of sensor in the pipe of the ice-
cream which senses the cup for the ice cream and opens the valve which is controlled by
the microcontroller. If there is no cup then it doesn’t sense the cup and value remains
close. The quantity and the time for the ice-cream to fall is calculated before the design.
As the filled cup move then there is automatic covering system which can be designed
similarly and is controlled by the microcontroller.
Fig.3.2 Schematic diagram for packaging of Ice Cream using 8255
PIC
MCU
8255
PIC
TIMING
CONTROLLING OF
VALVE
BELT
ICE CREAM

13. Case Study on Ice Cream Production
10
4. DISCUSSION AND CONCLUSION
Binny food industries whose brand name is “Quality ice cream” ,one of the pioneer
company of Nepal is manufacturing different varieties of Ice-creams such as vanilla,
strawberry, chocolate, Butter Scotch, Kesar Pista, Choco Bar, Strawberry bar, Pineapple
Bar, Orange Bar, Lichhi Bar etc. The most popular varieties are Vanilla, Choc bar and
Choc Paste. The quality of the ice cream is indicated by its brand name but the company
has not able to tap the many number of city market. It is limited to few cities like
Kathmandu, Biratnagar, Nepalgunj, and Pokhara.
In Nepal number of ice-cream manufacturing company is increasing day by day but
quality is declining, a Binny Food Industry (Quality ice cream) is capable of maintaining
and enhancing its name and fame but the price is high. It has launched many flavor ice
cream in the market for which essence are imported from India and other countries.
The technology used is semi-automatic .The packaging system is totally manual and
enhancing technique is explained above. Other system is automatic but the machines used
are old. It should give proper training to the staffs so that they can get their work easily.
For more enhancing a good planning is needed in the near future and think on reducing
the cost because everybody can’t get it.

14. Case Study on Ice Cream Production
11
5. Photo Gallery:
Fig. (a)
Fig. (b)
Fig. (c)

15. Case Study on Ice Cream Production
12
Fig. (d)
Fig. (e)
Fig. (f)

16. Case Study on Ice Cream Production
13
6. References:
i. http://www.pdf.aigroup.asn.au/environment/Bulla_case_study.pdf
ii. www.deatonengineering.com/case_studies/ice_cream.php