Study on Processing and Quality Parameters of Ice-cream
- 1. PROJECT REPORT INTERNSHIP IN DEVYANI FOOD INDUSTRIES Ltd. (Cream bell) Study on Processing and Quality Parameters of Ice-cream GUIDED BY Dr. I.P Singh Production manager Devyani Food Industries Ltd. Kosi Kalan, Mathura, Uttar Pradesh SUBMITTED BY Ankur Kumar Thathera M.Sc Food Technology Enroll no. M1410108
- 2. COMPANY PROFILE In 2003 RJ Corporation brought Cream bell ice cream to India in technical collaboration with French Dairy major, Candia. It is among the top 5 leading ice cream brands in India and is known for its quality product innovation. It has approximately 15% market share in the Indian ice cream industry with a presence in 19 states which covers the top 40 cities in India. Cream bell has four manufacturing plants across India: Baddi (Himachal Pradesh), Goa, Kosi Kalan (Uttar Pradesh) and Asansol, and 35,000 retail outlets across the country. Our plants are ISO 9001:2008 and ISO 22000:2005 certified.
- 3. 21 st century Ice cream brand. INDIA’s MOST PROMISING BRAND awarded by World Consulting & Research Corporation and process advisors Ernst & Young. Won 27 Highest-in-Category awards by Indian Dairy Association and DANISCO Spreading flavorful joys in neighboring country of Indian sub-continent. State-of-the-art equipment from reputed manufacturing in USA & Ital. We care about approvals, so we keep innovating.
- 5. PRODUCT PROFILE Ice cream is a frozen food, usually eaten as a dessert. The general ingredient of ice cream is dairy product such as milk, cream, fat often combined with fruits or other ingredients to enhance its palatability and acceptance by the consumer. The mix obtained by freezing a pasteurized mix prepared from milk, vegetable oil or fat in a combination with milk protein and vegetable protein, sugar, water, with or without maltodexterin and permitted stabilizer with or without chocolate paste and cocoa powder. Ice creams are made by a basic mix which when processed and added with flavors' makes the final ice cream. There are different type of mix that are used in different type of ice cream FROZEN DESSERT MIX ICE CREAM MIX KULFI MIX LICK CANDIES
- 6. TYPE OF MIX PROTEIN ACIDITY FAT TOTAL SOLID sample ice cream mix 3.74 0.117 7 37.62 frozen dessert mix 3.74 0.126 9 38.54 ice cream mix 3.82 0.144 11.4 40.56 premium mix 4.08 0.162 13 42.8 FD chocolate mix 3.82 0.198 10.4 42.8 ice cream chocolate mix 4.08 0.207 13.4 45.74 premium chocolate mix 4.08 0.207 14.4 44.58 ice cream special mix 3.82 0.144 7 38.2 premium special mix 4.08 0.153 10.6 40.6 sugar free ice cream 3.82 0.135 11.4 40.8 milky chocolate mix 3.74 0.189 7 38.2 premium chocolate special mix 4.08 0.198 13 48.6 Kulfi mix 4.08 0.162 13 42.8 Type of mix's & Quality parameter which are used in preparation of Ice cream
- 7. Types of syrup Several types of syrup differentiate on the basis of sugar content present in it Lick syrup (20%) Sorbet syrup (39%) Pop up syrup (17%) mango duet syrup (20%) Lychee duet syrup (24%) Strawberry double (20%)
- 8. PREPARATION OF MIX •Before staring of mix preparation we should ensure that all the row material approved by the QA department. •Testing of water done by QA (pH, TDS and hardness) •CIP of equipments cheeked by QA. •All Workers wears the gloves, apron and mask .
- 9. Mix preparation Liquiverter Water heated at 35C Addition of SMP Add maltodextrin at 40C Add sugar at 45C Add stabilizer at 55-60C with the same amount of sugar Addition Fat at 65C Duplex filter Mixing tank
- 10. PHE CHAMBER Balance tank (FDV) Regeneration Homogenization (1st 500 psi – 2nd 2000 psi) Heating 82C Holding 25 seconds Regeneration Cooling 25-30C Chilling 4-5C Aging 4 hours at 4C
- 11. Mix pass through the duplex filter Mix is properly pasteurized at 82C for 25 second Mix is left for minimum 4 hours at 4C for aging Testing of mix done during aging (fat, acidity, protein, total solid)
- 12. Once the mix is ready then it is passed to the colour and flavour Tank where further process is initiated. Aging tanks Color & flavor tanks Freezing/Whipping of ice cream Packaging Harding
- 13. On-Line Quality Parameters The fresh produced packed ice cream are analysed for its *as per product specification Fat* Titratable acidity* Protein* Total solid* pH* Brix*
- 14. Records to be maintained : ONLINE RECORD •Online Quality Parameters every 30 minutes during production. •Room temperature and Humidity in production area every 15 minutes. •Checking the batch number of every product. •Checking cold room temperature and Harding tunnel temperature every 30 min. •Check packaging of ice cream every 15 min. •Temperature of ice cream after passing through the Harding tunnel. •Weight of ice cream as per standard. • Net weight of inclusion every 30 min as per standard. •Overrun of ice cream as per standard.
- 15. Yield calculation •Yield calculated on the basis of cases I.e. packaged boxes obtained in one batch of production. •For eg: •Vanilla bulk pack 5 liter (M) 14 June-19/765 •Actual unit produced in one batch is 1392 Unit convert into liter •Formula •Volume of ice-cream in ml*unit/1000 =5000*438/1000 =2190 Standard mix used standard*unit =2.338*1392 =3254 Yield Standard/Actual =3254/1392 =101% yield