ICE CREAM SECTION

INTRODUCTION :- Ice cream is a frozen dessert typically made from a mixture of

cream/butter , milk and milk solids , sugar, stabilizer, emulsifier, glucose syrup, flavouring and
colouring , often with the incorporation of air during freezing to impart a smooth and creamy texture.

This delectable treat comes in various flavours, ranging from classic vanilla to innovative blends, and
may include additional ingredients such as fruits, nuts, chikki, choco chips etc. With its rich history and
widespread popularity, ice-cream stands as a beloved indulgence enjoyed worldwide, offering a
delightful sensory experience that combines taste, texture and temperature in a frozen symphony of
sweetness.

Capacity:- Dodla dairy manufactures 20,000 L ice cream during peak season and produces 10,000l
ice cream during regular season.
FSSAI standard for ICE-CREAM

Parameters Standards

Milk fat, minimum %(m/m) 10.0

Total solids, minimum %(m/m) 36.0

Milk protein, minimum %(m/m) 3.5

Weight, minimum g/l 525.0

Sugar 13 -15 %

Stabilizer Emulsifier 0.5 %

* protein content is 6.38 multiplied by the total nitrogen determined.

Dodla Standard for ICE-CREAM:-

S. No. Parameters Regular Fat Medium Fat

1. Fat (min) 11.5% 5.2%

2. SNF (min) 11% 11%

3. TS (min) 39% 34%

4. Moisture (max) 61% 66%

5. Added Sugar 17.4% 18%

6. Specific Gravity 0.525 0.525

7. PH 6.1 6.1

8. Overrun (max) 95% 95%

Ingredients used for making ice-cream mix:-

1) Dairy ingredient:- Milk, milk solids ( skim milk powder), cream/butter.

2) Non-dairy ingredient:- Sugar, stabilizer, emulsifier, glucose syrup, colour ,flavour.

Role of constitutes :-

 Milk Fat:- Milk fat in ice-cream contributes to its creamy texture and rich flavour. It helps
create a smooth mouth feel and provides a foundation for the development of various flavours.
The fat also helps stabilize the ice-cream structure and prevents it from becoming too icy by
coating ice crystals.
 Milk SNF (Solid Not Fat):- Milk SNF in ice-cream adds to its body and texture. SNF includes
proteins and lactose, contributing to the overall structure of the ice cream. While milk fat
provides creaminess, SNF helps give the ice-cream a more balanced consistency, enhancing its
mouthfeel and ensuring a satisfying texture.
 Sugar:- Sugar in ice-cream serves multiple roles. It sweetens the dessert, enhancing its
palatability, but it also plays a crucial role in the texture. Sugar lowers the freezing point of the
ice-cream mix, preventing it from becoming too hard. It contributes to a smoother texture by
interfering with the formation of ice crystals, resulting in a creamy consistency.
 Glucose syrup :- Glucose syrup in ice cream serves as a sweeteners and also plays a role in
texture. It helps prevent the formation of large ice crystals by reducing the freezing point of the
ice cream mix. This contributes to a smother and creamier texture, enhancing the overall quality
of the ice cream.
 Stabilizers :- The primary purpose for using stabilizer in ice cream are to increase mix
viscosity; to increase the perception of creaminess; to provide resistance to melting; to retard
the growth of ice and lactose crystals during storage, specially during periods of temperature
fluctuation; to prevent ‘ wheying off ’ ; and to help prevent shrinkage during storage. Many of
these functions are attributed to the enhanced viscosity of the ice cream mix.
 Emulsifiers :- Emulsifiers are used in ice cream to produce a drier ice cream with smoother
body and texture, to increase the resistance to rapid meltdown during consumption, and to
increase the resistance to shrinkage during storage ([^1]). These beneficial effects result from
the enhancement of partial coalescence of fat globules during the whipping and freezing stage.
 Flavours :- A wide range of flavourings are used in ice cream. Flavourings include natural and
artificial flavours , fruit, nuts, and bulky inclusions such as chocolate chunks and candies. Some
flavours used for making ice-cream in Dodla are :
a. Vanilla
b. Strawberry
c. Chocolate
d. Butter scotch
e. Black current
f. Rajbhog
g. Caramel
h. Sonpapdi
i. Mango
j. Orange
k. Grapes
l. Kesar pista & kesar badam
m. Anjir
n. Rose white
o. Gulkand
p. Pineapple
q. Honey
r. Litchi
s. Cotton candy
t. Kulfi
u. Cardamom
v. Raspberry
 Colours :- Colours play a crucial role in ice-cream, influencing consumer perception
and enjoyment. Vibrant hues often indicate flavour variety, enhancing visual appeal and
prompting a positive sensory experience. Additionally, color can evoke emotions and
memories, contributing to the overall pleasure of consuming ice-cream.
a) Apple green
b) Brilliant blue
c) Carmoisine
d) Sunset yellow
e) Tartrazine
f) Pink rose
g) Erythrosine
FLOW CHART :-

Milk, butter, SMP, sugar, glucose syrup, stabilizer, emulsifier QC-01

Receiving of ingredient through blender

Mixing of ingredient through PHE (65°C)

Magnet In line filter

Balance Tank

Homogenization { I - 2000psi , II – 500psi }

Pasteurization {Heating 85±2°C , Chilling to ≤55°C} CCP-01 F

Flow Diversion Valve (FDV)

Table inspections of nuts Ageing {min. 6-8hrs at ≤5°C} QC-02

Preparation of fruits and nuts Receiving in flavouring tank

Receipt of PM Preparation of flavour QC-03

Coding Addition of flavour & colour Extruder

Continuous Freezer {at -4±1°C} Air from FRL

Fruit Feeding Cup &Cone

Filling Filling

Packing & Crating Liquid waste to ETP

Hardening {at -18°C to -23°C} Solid waste to scrap

Deep Freezing & Storage

OPRP Despatch {at -18°C}

EQUIPMENT DETAILS :-

1. Mixing Tank
Company Name Neologic Engineering Pvt. Ltd
2kL
Capacity
Jacketed & Insulated
Type
2016-17
Date Of Installation

2. Pasteurizer
Company Name Alfa laval (India) Ltd.
2kL
Capacity
2016
Date Of Installation

3. Homogenizer:-
Company Name GEA Niro Soavi

2KL
Capacity
2016
Date Of Installation

4. Ageing Tank
Company Name Neologic Engineering Pvt. Ltd
4KL
Capacity
Jacketed & Insulated
Type
2016-17
Date Of Installation
5. Storage Tank

Company Name High Fat Medium Fat

Deccan Energy Supra Engineering

Appliances Nigam Works

Capacity 2K L 2K L

Type Insulated Insulated

Date of Installation 2019 2023

6. Flavouring Tank

Company name Neologic Engineers Pvt. Ltd.

Capacity

FT-1 600 L

FT-2 600 L

FT-3 600 L

FT-4 300 L

Date of installation 2016-17

7. Continuous Freezer

Company Tetra pack Synergy Tetra pack Synergy

Name continuous (manual ) continuous (Auto)
freezer (Auto) freezer (Auto)

Capacity 700 L / h 400 L / h 700 L / h 600 L / h

 Cooling R 404 R 404 R 404 R 404
Agent

Date Of 2016 2017 2018 2017

Installation

8. Cups & Cone Machine

Company name ISF Fillmatic 6000 LI

Capacity 1000 /hr

Date of installation 2017

9. Extruder Line

Company name Vojta Ice Cream Equipment

Capacity 6000 /hr

Date of installation 2017

10. Kulfi Vat

Company Name Deccan Energy Nigam

Capacity 500L

Date of Installation 2019

GENERAL MANUFACTURING PROCEDURE:-

Step-1: Standardization

Step-2: Blending ingredient

Step-3: Filtration

Step-4: Homogenization

Step-5: Pasteurization

Step-6: Ageing of mix

Step-7: Add liquid flavours and colours

Step-8: Continuous freezer

Step-9: Filling

Step-10: Hardening

Step-11: Cold Storage

Step-12: Despatch

STANDARDIZATION :-
Three varieties of processed milk are made in this section therefore standardization of milk s the
necessary and most important step to be taken in this section. For standardization purpose we use whole
milk, skim milk, cream, and SMP. Ice cream standardization is crucial for several reasons, impacting
both the consumer and the manufacturer. Here’s the breakdown of its importance:
For Consumers:
1.) Consistent quality: standardization ensures a consistent taste ,texture and mouth feel in every
scoop of ice cream
2.) Safety: standardized recipes guarantee that ice cream need specific safety and hygiene regulations.
This minimises the risk of food grown illness and ensure a safe and enjoyable treat for everyone.
For Manufacturers:
1) Cost efficiency: standardized recipes optime ingredient usage, minimising waste and production
costs. This allows manufacturer to offer ice cream at competitive prices while maintaining
profitability.
2) Quality control: standardization facilitates effective quality control measures. Manufacturers can
easily monitor and maintain consistent quality throughout the production process.
Purpose of standardization:

I. To make economical use of milk constituents.

II. To adjust the Fat and SNF.
BLENDING INGREDIENT :-
Firstly take milk into the mixing tank and pass through the hopper where other ingredients like SMP,
sugar, stabilizer and emulsifier are added simultaneously with the flow of milk. Butter and glucose
syrup are added directly to the mixing tank manually. After adding all the ingredients the mix is heated
continuously into the mixing until it reaches to 65°C.

S.No. INGREDIENTS AMOUNT (%) TEMPERATURE (°C)

01. Milk 60 <5

02. SMP 10.5 30-35

03. Sugar (17-18%) 80 45-50

04. Glucose syrup 3 50-55

05. Butter 11 50-55

06. Stabilizer & emulsifier with 0.5 60

remaining sugar(20%)
FILTRATION:-

After blending all the ingredient the mix should have to pass through filters i.e. first magnetic filter
and second micro filter. In magnetic filter, if the metal particles are present then it will retentate by the
magnetic filter. Now the filtered mix is pass through the micro filter to remove other unwanted
particles. The pore size of micro filter is 5mm.

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 2 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.

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. No one pressure can be
recommended that will give satisfactory results under all conditions. The higher the fat and total solids
in the mix, the lower the pressure should be. If a two stage homogenizer is used, a pressure of 2000 –
2500 psi on the first stage and 500 – 1000 psi on the second stage should be satisfactory under most
conditions. 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.

Principle of homogenization:-

The working principle of a homogenizer is that by passing coarse or large particles through a narrow
orifice under high pressure, the large particles can be converted into fine particles. The velocity in the
narrow slits range between 100 -250 m/sec. The high degree of stability and uniformity in the
homogenized material is achieved through the combined effort of three physical principles: shearing,
cavitation, and turbulence.

A) Shearing Effect

When large particles get trapped between fluid or sample layers of different velocities, they form a
shearing effect. The shear force generated breaks the large particles into smaller pieces.

B) Cavitation Effect

The cavitation effect occurs when there is a pressure drop in the fluid. The pump and homogenizing
valve are parts of the homogenizer that help to build and drop the pressure, respectively. Cavities are
formed when the vapor pressure exceeds the absolute pressure inside the homogenizer. Shock waves
released under the collapse of cavities break the particles in the sample.

C) Turbulence

The high velocity of the fluid creates turbulence within the fluid. The turbulent motion results in the
generation of eddy currents and heat, which help break down the particles.

Homogenizer operation for starting procedure:-

 Connect line from balance tank to PHE & PHE line to homogenizer & the homogenizer outlet
to pasteurizer.
 Open cooling water to homogenizer.
 Start the pasteurizer.
 Start the motor of homogenizer pump.
 Start the hydraulic pump.
 Turn slowly 2nd stage adjusting knob to get required pressure 500 psi (40Kg/cm²) .
 Turn the 1st stage adjusting knob to get required pressure 2200 to 2500 psi (140Kg/cm²).
Maintain the pressure constantly.
 Take mix to the balance tank and run with mix.
 After completion of production cycle, switch over to water.
 Release the pressure knob as follow:-

o First 1st stage pressure knob

o 2nd stage pressure knob
 Give CIP cycle to pasteurizer and homogenizer.
 While giving caustic cleaning and hot water cleaning maintain a 100Kg/cm² pressure for 10min
each.

Key Factor:-

• Follow stipulated pressure for different mixes.

• Never run the homogenizer without opening the cooling water.
PASTEURIZATION :-

For the dairy industry , the terms ” Pasteurisation “ , “pasteurised” and similar terms means the process
of heating every single particle of milk or milk product in properly designed and operated equipment ,
to a temperature of either 65°c for 30 minutes or 72°c for 15 seconds. There are five sections in
pasteurization: Regeneration 1, Regeneration 2, Heating section, Cooling section, Chilling section.

AGEING OF MIX :-

The ageing process of ice cream mix involves allowing it to rest in the refrigerator for a few hours
or overnight . This helps improve the texture and flavour by allowing the ingredients to blend and
the fats to solidify.

The ageing process in ice cream mix involves several key chemical reaction . During ageing:

1. Protein hydration: proteins in the mix hydrate, leading to better stability and a smoother texture.
2. Lipid crystallization: fats in the mix crystallize, creating a more stable structure and contributing to
creaminess.
3. Sugar dissolution: sugar dissolves further, reducing ice crystal formation and enhancing sweetness.
4. Emulsification: emulsifiers in the mix work to stabilize the fat – water interface, improving overall
stability and texture.
5. Flavour development: the interaction of various components during aging contributes to the
development and blending of flavours.

These chemical changes collectively result in a more homogenous and desirable ice cream texture
and flavour.

CONTINUOUS FREEZER :-

Principle of continuous freezing of mix : In this system, the mix and air are fed into the ice
cream freezer by arranging two feed pumps in series, with an air inlet valve between them. The first
pump regulates the rate of mix flow while the second one operates at a higher speed than the first.
This together with regulation of inlet valve, controls the quantity of air drawn into the mix and
provides the pressure for forcing the mixture through the freezer barrel.
Continuous ice cream freezing operation : A typical scraped surface freezer (SSF) consists
of a cylindrical barrel with a refrigerant, such as vaporizing ammonia or Freon, surrounding it.
Inside the barrel is a rotating shaft, or dasher, with scraper blades attached to it. Typically, the barrel
and dasher assembly are made of stainless steel. Ice cream may be frozen either in a batch or
continuous process. A batch process may take about 10 to 20 min to freeze. A continuous freezer,
common to large operations, has a residence time on the order of 1 to 2 min. The refrigerant
temperature is about −30◦C.

Description of continuous ice cream freezer : There is provision of a freezer barrel. Such
barrel is surrounded by a concentric outer cylinder carrying refrigerant of sufficient capacity to
freeze the mix flowing through the barrel to a plastic mass. The mix is frozen by the time the mix
passes through the length of the barrel. The mutator shaft rotates at several hundred revolutions per
minute within the barrel. The shaft carries knife blades so arranged that they continuously scrape
the ice cream from the barrel surface, as it freezes there. Since the space between the mutator and
the freezer barrel is less, the product passes through the barrel in a few seconds (5-15 sec) giving
rise to ‘instant’ freezing. A ‘solid mutator’ is used for production of harder, extruded ice cream,
while

for soft ice cream an ‘open mutator’ is available. Hollow mutator overcomes the problem of
sporadic ice accumulation on mutator resulting in high back pressure on the pumps. Moreover, they
provide greater flexibility in the freezing and whipping conditions. The clearance between the
mutator and the wall of the freezer tube is only ~ 5/16”. As a result, the mix is in the freezer for
only 5-15 sec. resulting in ‘Instant’ freezing.

Dashers are made in a variety of displacements, the percentage of the freezer barrel volume
occupied by the dasher. Solid dashers have high displacement, typically about 80%, whereas open
dashers have low displacement and often include beaters.

Pressure is maintained inside the barrel by a back pressure valve at the outlet of the freezer. Earlier
models used spring loaded valves, in later machines, it is controlled pneumatically. Maintenance of
correct back pressure helps in proper incorporation of air in small uniform cells throughout the mass
of product during freezing.
Working of a continuous ice cream freezer : The mix and air are pumped into the machine by
means of a two-stage pump (two separate pumps). The first stage pumps just the mix, while the
second stage pumping more rapidly (twice the capacity of first pump), creates suction between these
two stages and permits introduction of mix in controlled amounts. The second stage also provides
the pressure which propels the product through the freezing chamber and through the discharge
pipes. The air supply is drawn in through the air valve, which can be adjusted (20-30 psi pressure)
so as to obtain the desired amount of overrun. At the freezer outlet a spring loaded valve/pneumatic
valve assures back pressure on the freezing chamber so that air may be properly incorporated in ice
cream.

To produce ice cream in the typical commercial process, the ingredients are first mixed together,
then pasteurized, homogenized, cooled, and aged for at least 4 h at a temperature of about 4 ◦C.
Flavouring is then added before the mix is pumped into the scraped-surface freezer (SSF), where
about 50% of the water is frozen and air is incorporated into the product. Upon exiting the SSF,
inclusions and variegates may be added, and the soft product, at about −5 to −6 ◦C, is filled into its
retail container. In case, nut or fruit variety is to be made, the fruit or nut inclusion particulates can
be added into the exiting partly frozen ice cream through use of a ‘Fruit feeder machine’. The fruit
feeder is connected to the outlet of the freezer.

The ice cream is sent to harden until the core reaches a specified temperature, usually about −18
◦C. As the temperature drops and more ice crystallizes, the remaining water contains more and more
sugar, which depresses the freezing point so that in the final, hardened product, about 75- 90% of
the water is frozen. The finished product is stored between −18 and −30◦C, depending on the plant,
distributed, and sold. In the supermarket, temperatures in certain types of freezer cabinets
(particularly open-faced cabinets) can reach −9 ◦C, and in frost-free consumer freezers,
temperatures can vary quite widely during the frost-free cycle.

Changes that occur in ice cream mix during freezing : Initial freezing is a dynamic process:
the mix is frozen while being agitated, which whips in the air, destabilizes the fat, and scrapes ice
into the bulk fluid. Cold ice cream mix enters the freezer, with the refrigerant absorbing the heat in
the mix until the super-cooling at the wall is great enough to initiate ice nucleation. As ice crystals
form at the wall, the dasher blades scrape the surface layer from the wall about every 0.075 s,
assuming 4 blades with a dasher speed of 200 rpm, and propel the ice layer, at a temperature of −20
to −25◦C, into the bulk of the freezing ice cream mix. When the ice cream exits the freezer, it is
usually around −5 to −6 ◦C, and close to 50% of the water is frozen. The average ice crystal size
exiting an ice cream freezer is 20 to 30 μm.

Ice crystal size could increase with dasher speed because of the extra mechanical energy and
frictional heat being put into the system via the rotation of the dasher, which accelerates
recrystallization. Conversely, increasing dasher speed could help reduce ice crystal size by scraping

off a thinner ice layer. Hence it is reported that an optimum balance between rotation rate and heat
generation is required, which would depend on the individual freezer and ice cream mix
composition to produce the smallest ice crystals.

The operator’s principal work is to:

Regulate the amount of air being introduced into the mix to give the desired overrun.
Regulate the temperature of refrigerant in the freezing chamber.
Recirculation continuous ice cream freezer One potential modification to the typical ice
cream freezing process is to recirculate a portion of the product stream back to the freezer inlet
stream. The benefit of this practice is mainly for startup, where recirculation minimizes
production of unused unfrozen product. The recirculation stream brings existing ice crystals into
the mix where they can serve as seed crystals and can continue to grow in size. This results in a
wider residence time distribution with a higher average residence time and, thus, a larger, wider
crystal size distribution. Recirculation has a beneficial effect on the air cell size, however, because
of the extra whipping (through increased residence time), breaks the air cells into smaller bubbles.
Low-temperature continuous freezers In some models, there is a second freezer barrel so that
ice cream in fact receives a second freezing – device that increases the capacity of machine. By
rotating mutator at high speed in first barrel when ice cream is in early stages of freezing and
therefore of lower viscosity. The mutator is at a lower speed in the second barrel, when freezing
process is near completion and the product viscosity is high. In low temperature continuous freezer,
ice cream can be drawn at – 15°C. This type of freezer is useful for stiff extrusions or for filing bulk
cans (e.g. 2 gallon cans).
A new technology for reducing draw temperature and eliminating the need for hardening is cold
extrusion. The process reportedly improves both the sensory and shelf-life properties of the ice
cream. The low temperature extruder is placed after the normal SSF and can bring the draw
temperature down to −15 to −18◦C. The extruder may be in either a single-screw configuration,
which churns the ice cream around the screw, or a twin-screw configuration, which kneads and
churns the ice cream between two parallel screws. Both operate at a rotational rate of about 15 rpm.
In the extruder, high homogeneous local shear breaks up the fat globules, ice crystals, and air cells
into smaller units which improve the flowability of ice cream. Compared to conventional ice cream
freezing and hardening, including a twin-screw cold extruder reduces ice crystal and air cell size by
a factor of 2-3. The smaller fat globule aggregates resulting from the high shear in the cold extruder
impart a creamy texture to the ice cream, without a buttery defect, making the technology useful for
low-fat formulations. Such ice cream is more resistant to adverse handling conditions than regular
frozen ice cream.
Technical detail about Tetra Pak:-

1. Compressor power 5.4Kw

Refrigerant gas
2. R404A
Refrigerant content 1.75kg
3.
Cooling fluid for condenser Water
4.
Dasher motor power 3Kw
5.
Mix pump motor power 0.75Kw
6.
Overall installed power 9.1Kw
7.
Condenser water consumption:
8.
A) Well water +5°C (41°F) 600L/h
B) Main water +15°C (59°F) 800L/h
C) Tower water +28°C (82°F) 3100L/h
Water inlet/outlet connector ¾” pipe
9.
Mix inlet piping , outside ½” clamp
10.
 Ice cream outlet piping , outside 1” clamp
11.

(A) Manual CF. (B) Automatic CF

Overrun:-

Overrun is usually defined as the volume of ice cream obtained in excess of the volume of the mix. It
is usually expressed as percentage of overrun.

This increased volume is composed mainly of air incorporated during the freezing process. The amount
of air that should be incorporated depends upon the composition of the mix and the way it is processed,
and is regulated so as to give the percentage of over run or yield that will give proper body, texture and
palatability necessary to good quality ice cream
 Calculating overrun:-

Overrun can be calculated by weighing a container and making a note of it so it can be subtracted later.
Note how much the container weighs filled with liquid mix and subtract the container weight. Fill the
same container level with frozen product and note its weight.

Calculating overrun by volume basis :-

Volume of mix – Volume of icecream

𝑜𝑣𝑒𝑟𝑟𝑢𝑛 % =
Volume of mix

Calculating overrun by volume basis :-

Weight of mix – Weight of icecream × 100

𝑂𝑣𝑒𝑟𝑟𝑢𝑛 % =
weight of icecream

Too much air will produce a snowy, fluffy, unpalatable ice cream; too little air, a soggy, heavy product.
Five factors that are usually considered when determining the amount of overrun are:
1. Legal regulations enforced in the market area
2. TS content of the ice cream. High TS permit use of a higher overrun.
3. Bulky flavour ice creams require a lower overrun than plain ice cream in order to obtain an equally
desirable body and texture.
4. Selling price of ice cream
5. Type of package – bulk packages which are solid for ‘dipping’ usually contain 90-100per cent
overrun, while packages of the carry home type usually are more satisfactory if they contain 70-80 per
cent.
The ability to obtain overrun at the freezer depends partly on the concentration and type of ingredients
in the mix and on the freezing process itself. Sharpness of scrapper blades, speed of dasher, volume of
refrigerant passing over freezing chamber and temperature of refrigerant are important in determining
the overrun.
The factors that depress overrun includes
• Fat content
• MSNF content
• Corn syrup solids content
• Increased amount of stabilizer
• Fruits, cocoa and chocolate
• Excessive calcium salts
• Poor homogenization
• Amount of mix in batch freezer
• Insufficient refrigeration
• Mix too warm
• Dull freezer blades
• Freezing the mix to high stiffness.
The factor listed as enhancing overrun includes
• Sodium caseinate
• Whey solids
• Egg yolks
• Emulsifiers
• Certain stabilizers
• Certain salts
• Pasteurization of mix at higher temperature

To secure uniform overrun and yield, the following points should receive attention:
1. Uniformity in refrigerant temperature and rate of flow of refrigerant.
2. The use of overrun testers, Drawrite or Willman controls.
3. Uniform make, etc., of freezers.
4. Not too many freezers per worker.
5. Hopper systems for filling containers if both freezers are used.
6. The use of a system of checking the weight of packages or containers as they enter the hardening
room.
Overrun percentage in different variety of icecream:

Overrun 90% 65% 50% 0%

Variety of • Cups (40ml, • Chocobar • Matka • Malai kulfi
icecream 75ml,125ml) (35ml,60ml) Kulfi cone (50ml)
• Cone (50ml, • Belgium bar (100ml) • Juice bar
110ml) (70ml) (60ml)
• Tub (500ml)
• Cartoon (700ml)
• Bulk (4 L)

FILLING :-

[1]CUP AND CONE FILLING MACHINE:-

A cup and cone machine for ice cream typically dispenses ice cream into either cups or cones, providing
a convenient way to serve this frozen treat.

1) *Cup Cone Feeder:*

A cup cone feeder is a vital component in ice cream filling machines, responsible for dispensing cups
or cones to be filled with precision. Employing conveyor or rotary systems, it facilitates an automated
and continuous supply of containers, streamlining the production process in ice cream manufacturing.

2) *Cone Calibration:*
Cone calibration is the process of ensuring the accurate and consistent sizing of ice cream cones. This
step is crucial in maintaining uniformity in product presentation and portion control. Calibration
mechanisms help adjust and verify cone dimensions during manufacturing, contributing to a
standardized end product.

3) *Ice Cream Filler:*

An ice cream filler is the core component responsible for dispensing a controlled quantity of ice
cream into cups or cones. Using piston or pump mechanisms, these fillers ensure precision in
portioning, contributing to product consistency and efficiency in large-scale ice cream production.

4) *Nut Dispenser:*
A nut dispenser is a feature in some ice cream filling machines that automates the addition of nuts or
other toppings to enhance the ice cream. This mechanism precisely releases a predetermined quantity
of nuts, contributing to the overall flavour and texture of the final ice cream product.

5) *Lidding:*
Lidding is the process of covering ice cream cups with lids to protect and preserve the product. In ice
cream filling machines, a lidding mechanism is often integrated, ensuring a hygienic seal over the filled
cups. This step is crucial for packaging and transportation, maintaining the quality of the ice cream.

6) *Crimping:*
Crimping is the final step in the packaging process, where the sealed lids on ice cream cups
are securely fastened. This ensures product integrity and prevents contamination during storage and
distribution. The crimping mechanism completes the packaging cycle, preparing the ice cream for retail
or consumption.

7) *Cup/Cone Ejection:*:-
Cup/cone ejection is the final phase in the ice cream filling process, where filled cups or
cones are smoothly discharged from the filling machine. This mechanism ensures a seamless transition
from production to packaging, maintaining the efficiency of the manufacturing line. Whether using a
conveyor or rotary system, cup cone ejection is designed for precision and reliability, allowing for
continuous and automated production in ice cream processing.
 .

(a) Cup filling machine (b) Cone filling machine

[2] EXTRUDER LINE MACHINE:-

1) *Cutting Jaw:*
The cutting jaw is a crucial component in the extruder line responsible for precisely cutting
or portioning the extruded ice cream into desired shapes. It ensures uniformity and consistency in
the final product, facilitating efficient packaging and presentation.

2) *Stick Feeding:*
Stick feeding is the process of introducing wooden sticks into the extruded ice cream.
This mechanism ensures that each ice cream portion is appropriately equipped with a stick, enabling
convenient handling for consumers.

3) *Extruder Line Tunnel:*

The extruder line tunnel is a controlled environment where the ice cream is conveyed after
extrusion. It allows for the proper freezing and solidification of the ice cream before moving to
subsequent stages, contributing to the overall quality and texture of the final product. The
temperature inside the tunnel should be -38°C to -40°C to maintain the hardening of ice cream.
4) *Extruder Hammer:*
The extruder hammer is a part of the machinery that aids in the controlled and consistent
extrusion of ice cream. It plays a role in shaping the product as it emerges from the extruder,
contributing to the desired form and structure.

5) *Loading Robot:*
The loading robot is an automated system that efficiently places or positions components,
such as sticks or molds, onto the extruder line. It enhances the speed and accuracy of the production
process, reducing manual intervention and optimizing workflow.

6) *Lamella Stick Holder:*

The lamella stick holder is a mechanism designed to securely hold and position sticks
during the extrusion and freezing process. This ensures that the sticks are properly embedded in
the ice cream, allowing for consistent and reliable attachment.

7) *Choco Dip:*
Choco dip is a component in the extruder line responsible for coating or dipping the
extruded ice cream in chocolate or another coating material. This adds flavour, texture, and
visual appeal to the final product, enhancing its overall consumer experience.

8) *Unloading:*:-
The unloading mechanism is the final step in the extruder line where the finished and
coated ice cream products are carefully removed from the line for further processing or
packaging. This step completes the production cycle, preparing the ice cream for distribution
and consumption.
 Fig. Extruder line

HARDENING :-

When ice cream is drawn from the freezer and put into the container to be placed in
the hardening room , it has a semi-fluid consistency not stiff enough to hold its shape. The
freezing process is , therefore, continued without agitation during hardening until the
temperature of ice cream reaches -18°C (0°F) or below. Here , as in the freezer , quick hardening
is desirable, since slow hardening favours large ice crystals & coarseness, most operators allow
a hardening time of 12 hour.
The factor affecting hardening time are:
1. Size and shape of the ice cream package.
2. Speed of (cool) air circulation.
3. Temperature of cooling air.
4. Section of the hardening room.
5. Temperature of ice cream drawn from the freezer.
6. Composition of mix.
7. Percentage overrun in the ice cream being hardened.
 Temperature Temperature
S.No. Hardening systems
maintained (°C) maintained (°F)

Hardening rooms
18±1°C 64.6°F
HR-1
18±1°C 64.6°F
1. HR-2
69.8°F
DF-1 21±2°C
69.8°F
DF-2 21±2°C

2. Hardening tunnels -35°C to -40°C -31°F to -40°F

Hardening of ice cream refers to the process of making the ice cream firmer and more resistant
to melting. This is typically achieved by freezing the ice cream at lower temperatures or adding
ingredients that contribute to a firmer texture, such as stabilizers or emulsifiers. Hardening helps
maintain the shape and consistency of the ice cream during storage and transportation, ensuring a better
overall quality for consumers.

Fig. - Ice cream Hardening Room

COLD STORAGE :-

Cold storage of ice cream is crucial to maintain its quality and prevent melting. Ice cream is stored at
temperatures below freezing, usually around -20°C (-4°F) or lower. This prevents ice crystals from
forming, ensuring a smooth texture. Proper cold storage also helps preserve the flavour, colour, and
overall integrity of the ice cream until it reaches the consumer.

After the ice cream is hardened , it may be immediately marketed , or it may be stored for a week two
at the most . the operation of storage rooms is the same as for the hardening room with two exception:
the temperature should be maintain uniformly at a point between -23°C to -18°C (-10°F to 0°F ) and
the packages should be piled very close , to delay changes in ice cream temperature.

Some precaution to be observed in the operation of storage rooms are :

1. Provide facilities for calling for aid, should the operator accidentally be trapped inside.
2. Keep both an axe and a sledge hammer in a definite place just inside the door .
3. Avoid fluctuation in temperature .

Fig.- Icecream cold storage

DISPATCH:-

The dispatch of ice cream involves carefully packaging and shipping the product from the
manufacturing facility to distribution point or retailers. It required specialized transport with
temperature- controlled conditions to prevent melting and maintain the quality of the ice cream during
transit. Quick and efficient dispatch is crucial to ensure that the ice cream riches consumers in optimal
condition , with its texture and flavour preserved . when the transport vehicles reaches at temperature -
15°C the loading should be started .

Dispatch Vehicles:

S.No. No of crates vehicle Vehicle no. Capacity

1. 420 crates  TS05UE1115 15KL

 AP24TC5442

2. 305 crates  TS05UD1848 9KL

 TS08UB7119
 TS05UF6324

3. 288 Crates  AP39UD5749 9KL

4. 220 Crates  AP39TZ4678 6KL

5. 135 Crates  TS05UB3310 6KL

 TS05UB7709

6. 90 Crates  TS05UA0776 3KL

 TS05UE3692

7. 45 Crates  TS05UD7719 2KL

Distribution Area :

1) Karnataka :
a) Bangalore
b) Kirwatti
c) Indragiri
d) Ballari
2) Andhra Pradesh :
a) Nellore
b) Penumuru
c) Chendurthe
d) Nizamabad
e) Ananthapur
f) Rajahmundry
g) Guntur
h) Vijayawada
i) Vizag
j) Kurnool
k) Ongole
l) Nellore
m) Sattenapalle
3) Tamil Nadu :
a) Chennai
4) Telangana :
a) Ramanthapur
b) Siddipet
c) Lb Nagar
d) Bahadurpally
e) Bachupally
f) Boduppal
g) Karimnagar
h) Manikonda
i) Masab Tank
j) Kairathabad
k) Vemulawada
l) Gundrampally
m) Mahabub nagar
n) Medak
o) Kukatpally

 Price Chart of Icecream:-

S.No. Product Variety Quantity Prices Per ml

price
1. Junior Choco Bar 35ml 15 0.25
2. Senior Choco Bar 60ml 20 0.33
3. Juice Bar 60ml 10 0.17
4. Belgium Chocolate Bar 70ml 50 0.71
5. Ice cream Cone 50ml 20 0.40
6. Ice cream Cone 110ml 40 0.36
7. Kulfi Cone 50ml 30 0.60
8. Ice cream Cup 40ml 10 0.25
9. Ice cream Cup 75ml 20 0.26
10. Ice cream Cup 125ml 40 0.32
11. Ice cream Tub 500ml 170 0.34
12. Ice cream Cartoon 700ml 280 0.40
13. Matka kulfi 100ml 60 0.60
14. Ice cream Bulk 4L 585 0.146
  Nutritional information of ice cream :( For cup ice creams):-

Nutrient Composition

Energy 81Kcal
Total Fat 4.4g
Energy from fat 39Kcal
Saturated fatty acid 2.7g
Cholesterol 11mg
Total carbohydrates 8.8g
Added sugar 6.4g
Protein 1.6g
Calcium 63mg

 Nutritional information of ice cream :(For cone ice creams)

Nutrient Composition
Energy 108Kcal
Total Fat 5.85g
Energy from fat 52.4Kcal
Saturated fatty acid 3.6g
Cholesterol 14.5mg
Total carbohydrates 11.75g
Added sugar 8.5g
Protein 2.1g
Calcium 84mg
 Nutritional information of ice cream :(For chocobar ice creams)

Nutrient Composition
Energy 108Kcal
Total Fat 6.9g
Saturated fatty acid 4.1
Cholesterol 25mg
Total carbohydrates 10.4
Added sugar 8.5g
Protein 1.0g
Sodium 24mg

Variety Of Products And Their Quantity:-

S.No. Product Variety Quantity No. of ice cream No. of CBX

in 1 CBX in 1 crates
1. Junior Choco Bar 35ml 16 pcs 14
2. Senior Choco Bar 60ml 14 10
3. Juice Bar 60ml 14 10
4. Belgium Chocolate Bar 70ml 7 10
5. Ice cream Cone 50ml 16 18
6. Ice cream Cone 110ml 16 8
7. Kulfi Cone 50ml 8 8
8. Ice cream Cup 40ml 12 12
9. Ice cream Cup 75ml 18 8
10. Ice cream Cup 125ml 6 16
11. Ice cream Tub 500ml - 52
12. Ice cream Cartoon 700ml - 36
13. Matka kulfi 100ml - 12
14. Ice cream Bulk 4L - 4
 SHELF LIFE :- Shelf life of Ice cream of DODLA dairy is 1 year (storage
under refrigerated condition below -18°C until “Use By date”.

KULFI :-
Kulfis an indigenous frozen milk product. The method of manufacture
of kulfi varies widely. The conventional method of kulfi making consists of boiling of
milk, addition of sugar, concentration of milk to 2:1 level and khoa, malai, flavour etc.
to the concentrated cooled milk. Kulfi mix is then filled into metallic cones and the top
of the cone is covered with lid. The mixture in the moulds is frozen in large earthen
vessels containing ice-salt mixture in the ratio of 1:1.

COMPOTION OF KULFI :-
Compositional characteristics of kulfi mix :-

s.no. Parameters Percentage

01. Fat 10.12
02. SNF 20.25
03. Total solids 45.03
04. Protein 8.84

PREPARATION OF KULFI :-
1. In the industrial process the ingredients used are the same as for ice cream - milk, cream,
skim milk powder, sugar and stabilizer. Water is added to dilute the mixture (not having
stabilizer and a small amount of sugar).
2. The required quantity of ingredients are taken in an open steam kettle and the contents
heated with vigorous agitation.
3. When the mixture has been concentrated approximately two times, the stabilizer blended
with a little sugar is added to the concentrated mix and the heating and agitation
continued till the mix has been concentrated three times.
4. Ensure proper cleaning of kulfi moulds before startup the production.
5. Fill the blended mix with kulfi into the kulfi moulds.
6. Keep the kulfi moulds into the brine solution tank and maintain -18 to -25°C.
7. Insert the sticks into product within 5-8 minutes after keeping into brine solution tank.
8. Place the lids of tasty kulfi on sticks immediately.
9. After 25 minutes moulds to be removed from the brine tank and kept into the de-moulding
tank maintained at 30-40°C for 3-5 seconds.
10. After that product to be removed from moulds and kept plastic cones.
11. Packed the above tasty kulfi in corrugated boxes, and transfer in to the hardener until
hard via metal detector.
12. After that store into cold store at -18 to -25°C.

Fig. – Kulfi Preparation Vat

Fig. – Kulfi filling Fig. - Kulfi capping

Matka Kulfi :

Matka kulfi is another variety of kulfi. There is a small difference between

matka kulfi and malai kulfi cone (kulfi) i.e. Matka kulfi has 50% overrun and directly packed
into earthen pots with the help of continuous freezer, whereas malai kulfi cone has 0%
overrun and are packed manually in polypropylene cone packaging materials. Some
flavours, colours and dry fruits are also added into it to make kulfi more premium or
luxurious.
LOLLYS:-

Made of fruit juices, sugar & stabilizer with or without additional

fruits, colour, flavouring or water and frozen to the consistency of ice cream. Usually
contains 20-38% sugar & no dairy products.

Composition:-

S.No. Parameter Percentage %

1. Water 69.6

2. Total Solid 30.4

3. Sugar 23.0

4. Stabilizer & Emulsifier 0.4

5. Brix 28

6. pH 2.2 – 2.4

Fig. - Lolly preparation

Packaging Material Used in all variety of Ice cream :

S.No. Type Material

1. Cups Polystyrene (6)

2. Cone Paper

3. Cup & Cone lid Paper

4. Kulfi Cone Polystyrene (6)

5. Kulfi Lid Polystyrene (6)

6. Chocobar Wrapping film Other(7)

7. Matka Kulfi Clay pot

8. CBX Corrugated Cardboard Box

9. Stick Wooden Stick

10. Spoon Stainless Steel & Wooden

Fig. – Packaging
Allergen:-
A substance or ingredient that causes an allergic reaction is called as allergen.
In icecream some of the ingredient may act like an allergen which can sometimes cause
severe effect on consumers. Some of the allergen found in icecream are :

 Milk
 Soy
 Nuts
 Sulphite
 Wheat etc.

 CIP for ice cream section:

● Rinse with normal water.

● Rinse with hot water @ 80˚C for 5 min.

● Caustic rinse @ 86˚C/30min.

● Intermediate rinse with hot water for 5 min.

● Acid rinse @ 85˚C/30min.

● Now final rinse with hot water.

 Q.C check for ice cream:

● Organoleptic test
● MBRT
● Phosphates
● P.H
● Acidity
● Viscosity
● Specific Gravity
● CLR
● Fat
● Total solids
● Homogenization efficiency
● Over run
● Coliforms
● Yeast &moulds
● Total plate count