ICE CREAM

Definition:

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

According to the PFA rules (1976), ice cream may be defined as a frozen product obtained from the cow or buffalo milk or a combination thereof or from cream and/or other milk products, with or without the addition of cane sugar, eggs, fruits, fruit juices, preserved fruits, nuts, chocolate, edible flavours and permitted food colours. It may contain permitted stabilizers and emulsifiers not exceeding 0.5 per cent by weight. The mixture must be suitably heated before freezing. The ice cream should contain not less than 10% milk fat, 3.5% protein, and 36% total solids.

Different varieties of ice creams are available in the market catering to the varied tastes of the consumers. They are plain, chocolate, fruit, nut, milk ices or milk lollies, fancy moulded, novelties and softy ice creams. An average quality ice cream should have 10% milk fat, 10-11% solids not fat, 13-15% sugar, 0.3-0.5% stabilizer and emulsifier and total solids content in the range of 35-37%. If it has to be a good quality ice cream, it should have 12% milk fat, 11% solids not fat, 15% sugar, 0.30% stabilizer and emulsifier and total solids 39%.

Standards:

1. Chemical

Characteristics Requirements

Weight(g/t)(min) 525

Total solid(%wt)(min) 36

Milk fat(%wt)(min) 10

Acidity(%lactic acid)(max) 0.25

Stabilizer/emulsifier)(%wt)(max) 0.5

sucrose)(%wt)(max) 15

2. Microboilogical

Test Limit

Standard plate count(per g) Not more than 250000

coliform(per g) Not more than 90

Phosphates test negative

Approximate composition of commercial Ice Cream (as a percentage)

Milk fat milk solids-not-fat sugar stabilizer & emulsifier Total solids

Economy Ice cream

10 10 to 11 13 to 15 .0.30 to 0. 50 35 to 37

Good average Ice cream

12 11 15 0.30 37.5 to 39

Role of the constituents in Ice cream:

(a) Milk fat. This is high in food value, but expensive. It enriches and mellows the ice cream, giving it a full, rich, creamy flavour. If the milk fat is even slightly off-flavoured, the defect will be noticeable. The fat also contributes to the body and melting resistance of ice cream while producing a smoothness of texture. Fat also gives stability to the ice cream impairs whipping ability.

(b) Milk-solids –non fat (MSNF).also known as serum solids, they consist of milk proteins, milk sugar and mineral matter. They are high in food value and also food inexpensive. They add very little to the smell, but improve its body and texture. However, milk sugar adds to the sweet taste. The milk proteins help to make ice cream more compact smooth. Milk-solids-not-fat should be added in as large quantity as possible without risking the danger of sandiness.

(c) Sugar. The main function of sugar is to increase the acceptability of ice cream. The desired sweetening effect is only produced by sucrose. Sugars are usually the cheapest source of total solids in the mix.

(d) Stabilisers. These are produced to prevent the formation of objectionably large ice crystals in ice cream, especially during storage. Since they are added in very small quantities, they have a negligible influence on food value and flavour.

(e) Emulsifiers. These are used mainly to improve upon and provide a uniform whipping quality to the mixture, and produce a drier ice cream with smoother body and texture.

(f) Flavours and colour. Flavour increases the acceptability of ice cream, and colour its aesthetic appeal.

Flow chart for Ice Cream preparation:

Wet Mix Dry Mix

(Milk + Butter) (Sugar + Skim milk powder)

Heat to 60ºc Stabilizer with a small amount of sugar

Addition

Heat continuously (80ºc/15 min)

Homogenize

Ageing (-4ºc/10-24 hr)

Continuous/ batch freezer (-4ºc)

Filling

Cup Cone

(Prior filling –add chocolate and nut to cone wafer)

Hardening (-25ºc/4 hrs)

Maintain at -25ºc

Storage and distribution

Equipment Requirement for Ice Cream Processing:

S.No Equipment Quantity

Amount(Rs.)

1 Batch pasteurizer1

178550

2 homogenizer1

228000

3 Double section PHE1

78040

4 Chilled water generation system1

518001

5 Continues Ice-cream freezer1

431046

6 Ageing vat with refrigeration1

280000

7 Utility piping - 135000

8 Flavour Tank1

63250

9 Harding tunnel1

150000

10 Push cart glycol chillers2

113684

11 Cup filling machine 1

198306

12 Blast freezer 6 mould1

221729

13 Mobile cold Room +5⁰c1

222222

14 Mobile Cold Room -20⁰c1

222222

15 Electrical Panel - 22027

16 Cooling Tower1

41461

17 Cooling Tower pump 1

7342

18 Inter connect SS pipe 17622

Cost analysis for ice cream:

For 10 liters milk

Tabulation of raw ingredients cost:

S.NO Ingredients Quantity Price1 Raw milk 1 litre Rs.502 Butter 1kg Rs.3203 Milk powder 1kg Rs.3404 Sugar 1kg Rs.405 Stabilizer 1kg Rs.2506 Chocolate 1kg Rs.275

Cost analysis for ice cream ingredient mix:

Butter = 1kg

=1×320

= Rs.320

Milk powder = 1kg

= 1×340

=Rs. 340

Sugar =2 ½ kg

=2 ½ ×40

= Rs.100

Stabilizer =30g

= 30×250

= Rs.7.5

Chocolate = 250g

= 250×275

= Rs. 70

Nuts = Rs.100

General information:

1HP = 750 watts

1unit = 1000 watts

1unit = Rs.10

1 liter (milk) = 28 cups, 12cones

40 liter (milk) = 1kg chocolate

Cost analysis:

S.No Requirements Quantity Total Cost1 Packaging cost

1. Per cup2. Per cone

Rs.1.50Rs.2.50

2Processing costElectricity cost

1. Heater(1)2. Heater (2)3. Transfer pump4. Homogenizer5. Glycol pump 6. Cooling tower

pump7. Glycol chiller8. Total electricity9. Aging vat10. Hardening

chambers (4hrs)11. Freezer

2.66HP0.33HP1HP3HP½ HP½ HP3HP10.99 HP/hr3HP4.5HP

4HP

Rs.82/hr RS.540/hrRS.135/4hrs

Rs.30/hr

3 Total production cost = Rs. 25259 (cone)= Rs. 2644 (cup)

4 Selling priceIce cream 280 cups

120 cupsRs.2520 (cups)Rs. 2400 (cones)

Profit and loss analysis:

Profit = selling price – production cost (cups)

= 2520 – 2644

= Rs. -124

Profit = selling price – production cost (cones)

= Rs. 2400 – Rs. 2525

= Rs. -125

Ice Cream Manufacture process:

EQUIPMENT FOR ICE CREAM PROCESSING:

PASTURIZER

HOMOGENIZER

GLYCOL CHILLER

AGEING VAT

ICE CREAM FILLER

HARDENING TUNNEL

BLAST FREEZER

COOLING TOWER