STUDIES ON MANUFACTURING PROCESS OF DIFFERENT TYPES

OF ICE CREAM

Project Report
Submitted to the
College of Dairy Science & Technology , Luvas (Hisar, Haryana)
In partial fulfillment of the requirements for the degree
of
Bachelor of Technology
(Dairy Technology)

By:-

Rahul(2021DT19B)

Internship Period :-1/02/2025 To 30/06/2025(5Months)

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 DECLARATION
I hereby declare that this submission is my own work and that to the best of my
knowledge and belief, it contains no material previously published or written by
another person nor material which to a substantial extent has been accepted for the
award of any other degree or diploma of the university or other institute of higher
learning, except where due acknowledgment has been made in the text.

Rahul

(2021DT19B)

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 Abstract

This report is a summary of all the work experience, I have been able to gather
during 8th semester training in DEV MILK FOODS PVT.LTD. During training
period. I came to know the complete background of the factory, I have been
involved in the production of different types of ice cream.

The physicochemical and functional properties of ice cream are significantly

influenced by its fat content and the stabilizers used in its formulation. This study
aims to investigate the effects of varying levels of fat and stabilizers on the
quality attributes of ice cream, including texture, melting rate, overrun, and
sensory characteristics. Fat plays a crucial role in providing creaminess,
smoothness, and richness to ice cream, while stabilizers help maintain the desired
consistency and inhibit ice crystal growth during storage. Various formulations
were prepared with different fat concentrations (low, medium, and high) and
stabilizers (0.69%,0.6%,0.54%). Comprehensive analyses were conducted to
assess the impact on viscosity, T.S., melting study, and overall acceptability of the
ice cream. The results demonstrated that higher fat levels improved the mouthfeel
and reduced the rate of melting, whereas the choice and concentration of
stabilizers significantly affected the texture and stability of the product. The
optimal combination of fat and stabilizers resulted in an ice cream with enhanced
structural integrity, desirable sensory attributes, and prolonged shelf life. This
study provides valuable insights for the dairy industry in optimizing ice cream
formulations to achieve superior quality and consumer satisfaction.

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 ACKNOWLEDGMENT

I express my sincere gratitude to Mr. Hardip Shingh(Quality Manager)& Mr.

Mohammad Shahid(Plant Manager), of Dev Milk Foods Pvt. Ltd. (Frubon)
throughout my project. I am extremely thankful to them for being my constant
guiding force during completion of my project.

I am also thankful to all the technical and non-technical staff of our college for
their sincere cooperation during the project study.

I owe my deepest regards to my family and friends who have motivated me, kept
patience and supported me throughout my project work.

At last but not the least I express my heartfelt gratitude to almighty.

Date: June 2025 Rahul(2021DT19B) Place:

Hisar

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 List of content
S.No Title Pg.no
1 Declaration (ii)
2 Certificate 1 (iii)
3 Certificate 2 (iv)
4 Abstract (v)
5 Acknowledgments (vi)
7 Introduction 1
8 History of Frubon 13
9 Ingredients 15
10 Ice cream making steps 15

11 Current market 18
segmentation

12 Management 21
hierarthy
13 Organization structure 22

14 Corporate information 22

15 Plant layout 23
16 Production hall 24
layout

17 Products 29
18 Cup ice Cream 33
19 Frulicks 35
20 Frufles 36
21 Frudolly 38
22 Frupop 39

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23 Chocobon 41
24 Frucone 43
25 Frujoy 44
26 Casata slices 45
27 Matkakulfi 47
28 Frudae 49
29 Frupple 50
30 Frublast 51
31 Sweet surprise 52
32 QC LAB 54

33 Project 58

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 List of figures
S.no Title Pg.no
1 Outer view of 14
industry

2 Colouring 16
&Flavouring
3 Cone / Cup 17
Filler
4 Candy Making 18
Machines
5 Current 18
Market
Segmentation
6 Geographical 19
Representation
(Capital
Territory)
7 Organizational 21
structure

8 Layout of Plant 23
9 Production 24
Hall Layout Of
Ice Cream
10 Manual candy 26
machine

11 Cone filling and 27

Packaging
Machine

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12 Cup Filling 27
Machine
13 Auto Candy 28
Machine
14 Processing of 34
Cup Ice -
Cream
15 Processing of 35
Frulicks
16 Frufles 37
Processing
17 Frudolly 39
Processing
18 FruPop 40
Processing
19 Chocobon 42
Processing
20 Frucone 44
Processing
21 Frujoy 45
Processing
22 Casata Slice 47
Processing
23 Matka - Kulfi 48
Processing
24 Frudae & 50
Frupplr
Processing

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 25 Frublast 51
Processing
26 Sweet Surprise 52

List of Tables
s.no Title Pg.no
1 Top ice 12
cream
consuming
countries
2 Information of 29
products

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Chapter#1

INTRODUCTION
HISTORY OF ICE CREAM

Once upon a time, hundreds of years ago, Charles I of England hosted a

sumptuous state banquet for many of his friends and family. The meal, consisting
of many delicacies of the day, had been simply superb But the‟ „coup de grace’
was yet to come. After much preparation, the king’sFrench chief had concocted an
apparently new dish. It was cold and resembled fresh fallen snow but was much
creamier and wetter than any other was after dinner dessert. The guests were
delighted, as was Charles, who summoned the cook and asked him not to divulge
the recipe for his frozen cream. The king wanted the delicacy to be served only at
the Royal table and offered the cook 500 pounds a year to keep it that way some
later, however poor Charles feel in disfavour with his people and was beheaded in
1649. But by that time, the secret of the frozen cream remained a secret no more.
The cook, named De Mirco, had not kept his promise. This story is just one of
many of the fascinating tales which surround the evolution of our country’s most
popular dessert, ice cream. It is likely that ice cream was not invented, but rather
came to be over years of similar efforts, Indeed, the Roman Emperor Nero laudius
Caesar is said to have sent his slave to bring snow to freeze Ice cream (derived
from earlier cream ice) is a sweetened frozen food typically eaten as a snack or
dessert. It may be made from dairy milk or cream and is flavoured with a
sweetener, either sugar or an alternative, and a spice, such as cocoa or vanilla, or
with fruit such as strawberries or peaches. It can also be made by whisking a
flavored cream base and liquid nitrogen together. Colorings are sometimes added,
in addition to stabilizers. The mixture is cooled below the freezing point of water
and stirred to incorporate air spaces and to prevent detectable ice crystals from
forming. The result is a smooth, semi-solid foam that is solid at very low
temperatures (below 2 °C or 35 °F). It becomes more malleable as its temperature
increases.

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why ice cream is popular?

Anyone who’s experienced pangs of hunger and cravings when looking at an ice
cream cone can attest that the sugary, creamy treat is near irresistible. And it’s not
just because our bodies, and taste buds, have evolved to crave sugar on the
regular.

The Top Ice Cream Consuming Countries Of The World

Country Per capita ice-cream consumption

(litres/year)

New Zealand 28.4

United States 20.8
Australia 18.0
Finland 14.2
Sweden 12.0
Canada 10.6
Denmark 9.8
Ireland 8.4
Italy 8.0
United Kingdom 7.0

Table - 1 top ice cream consuming countries

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1

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 History of Frubon Ice creams

The Story

We live in an age where flavours have crossed their traditional defined boundaries.
Flavours, now play the role of a social connector or a reason to bond at every
occasion or celebration. The name Frubon is the amalgamation of two words
namely Fru (derived from Fruit) and Bon (means Good in French). The name
simply conveys the message that each product in the Frubon portfolio would
essentially carry ‘freshness’ and ‘goodness’ as two intrinsic values. At the core of
it, Frubon is the celebration of moments and certainly a compliment to the bond of
flavours. In a nutshell, it is the expansion of the passion to deliver value without
any compromise, everytime and everywhere.

About The Company

Dev Milk Foods (DMF) is Rajasthan´s leading milk and dairy brand with
footprints across length and breadth of the state. Since its inception in 2004, DMF
has successfully diversified its operations outside the domain of milk & dairy
products and ventured into the areas of manufacturing, marketing and
transportation. The company had pioneered the private dairy business in Rajasthan
and is now setting new benchmarks for the industry.

In its quest to explore new horizons of business and quality excellence, DMF has
come up with its world-class Ice Cream & Bakery brand ´FruBon´. Each product
under the FruBon brand umbrella is a blend of finest and best quality food
material.
FruBon is DMF’s most ambitious project till date that aims at delivering one-of-
itskind flavour experiences for all age groups. Spread across 60,000 square feet,
FruBon’s manufacturing unit is one of the most advanced Dairy, Ice Cream &
Bakery setups in Northern India.

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Outside its regular area of operations, DMF´s interests also include Education &
Early childhood care and education (ECCE).

Vision

To be the most Innovative & Admired food company of the world.”

Mission

• To create value for all stake holders of the company including

farmers, customers, employees, society & environment.

• To ensure the best food quality and flavour experience delivery to

customers through innovation and superior manufacturing processes.

• To attain sustainable & inclusive growth across regional, national and at

the global level.

Figure -1 outer view of the industry

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Infrastructure

DMF’s state of art manufacturing plant is located at the premium business

destination of Rajasthan i.e., Mahindra World City, Jaipur. Spread across an area
of over 60,000 Sq, ft., the manufacturing plant is one of the most modern plants of
Northern India. The plant is equipped with latest testing and manufacturing
facilities. Special care has been taken for recycling and re-usage of water. The
water recycled using ETP is utilized for cleaning & gardening. Provision for
ample ventilation and fresh light has been kept to reduce the carbon footprint and
dependency on electricity during day time. It is our continuous endeavour to
create value for our one of the most important stake holders i.e., Environment.

CORE BENEFITS

Core benefits of the Yummy Ice Cream Company are pure milk & butter used to
make it and also the great flavors, less fat and more fruits. The new ingredients
are called ‘Ice Structuring Protein’ (ISP). This protein allows us to make ice-
cream and ice bar which are lower in fat, sugar and calories and at the same time
include more fruits. We can also now make ice creams and ice bar which cannot
melt easily which is a great thing for small children and for hot countries.

INGREDIENTS

Ice cream is made from ice (water), milk, butter, fat sugar, milk powder, glucose
stabilizers, food grade color, artificial flavors, emulsifier, and natural flavors &
colors. All of these ingredients necessary for you in your diet to lead an active
lifestyle. From these ingredients you get protein that helps to build body tissues,
carbohydrates and fats which give you energy and essential vitamins and minerals
like calcium that help to strengthen bones and teeth.

ICE CREAM MAKING STEPS

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1. MATERIAL

Fresh milk, milk powder, sugar, glucose, stabilizer/emulsifier, food grade, colors,
flavors, fruit pulp, dry fruits.

2. PASTEURIZATION

Selected ingredients with balance formulation are then heated into a tank called
pasteurizing vat at 85℃ To kill all pathogenic bacteria.

3. HOMOGENIZATION

After heating the mix is now homogenize at high pressure of 2000 lb / sq in to

make a homogeneous mix.

4. COOLING AGING

After homogenization the mix is now cool down by plate cooler to 4C And kept
at this temperature from 2-24 hrs are called the aging process.

5. COLOURING AND FLAVOURING

This cooled and aged mix is now either and flavor by artificial colors and flavors
or food like Mango ice cream.

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 Figure -2 addition of color and flavour

6. Freezing

Continuous freezer is a machine, which makes ice cream. It consists of mix pump,
which pulls pre-cooled flavored mix along with air (called air-run) into barrel of
freezer. Barrel consists of dasher with very sharp blades. These blades scrape the
frozen mix from the sidewalls of barrel at eject out in form of semi solid ice cream
at temperature of 4 C To 6 C.

7. CUP/ CONE FILLER

The semi solid ice cream from continuous freezer is now filled into cups or cones
by automatic filling machine called cups / cones filler and then transferred into
hardening room at a temperature of -35 C. For further hardening.

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 Figure no.3 cone filler

8. CANDY MAKING MACHINES (ROLLO 20, ROLLO 32, CANADY)

These are sticks making machine. Rollo 20 and 32 are semi aromatic units where
as candy is a manual stick making machine. Process consists of filling ice cream
into moulds. Moulds are kept into brine solution (a solution of CaCl2) at a
temperature of -30 to -40 C.

. Wooden sticks are then inserted automatically in case of R-20 & 32 but manual
in case of candy. After hardening the moulds are defrosted by warm water and ice
cream sticks come out which are then packed automatically in pearl paper which
then placed into card board boxes and shifted into hardening room for future
hardening, From hardening room, the ice cream is shifted into cold rooms at a
temperature of -25 C.

Figure -4 candy making machine

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 CURRENT MARKET SEGMENTATION

Current marketing segmentation of Yummy Ice Cream is as under:

1. Geographic Segmentation
2. Demographic Segmentation
3. Psychographic Segmentation
4. Behavioral Segmentation

Figure-5 market segmentation

Geographic segmentation

In geographic segmentation the company divided each city into different segments
according to Areas, States, Regions, and Markets. Yummy Ice Cream is targeting
as geographic segmentation of the India. We are targeting now the main cities of
provinces as:I.

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 Capital Territory
1. Rajasthan
2. Haryana

Figure-6 capital territory of frubon

Demographic Segmentation

In Demographic segmentation we will divide people according to their ages and

life cycle. We will divide our customers regarding their ages as children,
teenagers, twenty plus, thirty plus, and so on more than fifty years old. But when
we think about the children, they are more interested to eat ice cream of different
flavors.

Psychographic Segmentation

The psychographic segmenting is done on the basis of the taste and health
conscious consumer frubon is targeted its market by creating an image of high
quality and hygienic products.

Behavioural Segmentation

Behavioural segmentation divides buyers into groups, based on their Knowledge,

Attitude, Uses, or Responses about the products. We also believe like many

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 marketers that behaviour are the best starting point for building the best market
segmentation. To make the best marketing structure we can set a reasonable price
which is suitable for all types of social classes in India. By using focus strategies
in which they just target the segment of sufficient size, not crucial to success of
major competitors and they are not attempting to specialize in the same target
segment.

DEPARTEMENTS OF FRUBON

1. Department of Research
2. Department of Marketing and Sales
3. Department of Administration / Human Resources
4. Department of Accounts
5. Department of Finance
6. Engineering Department
7. Shipping Department
8. Development / Food Technology
9. Packaging: Multiple packaging

Chapter#2

MANAGEMENTHIERARCHY

1. Mr. Dharam Dev Verma ( Managing Director)

2. Mr. RohitVerma ( Director)
3. Mr. MukeshRastogi (CEO)
4. Mr. Mohammad Sayed (Plant manager)
5. Mr. M. K. Agarwal(Dairy section General manager)
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6. Mr. Pankaj Shukla (Ice cream Section manager)
7. Mr. Hardeep Singh (Quality manager) Organizational Structure of

Frubon

Figure-7 organizational structure of frubon

Corporate Information

Contact

Dev Milk Foods Pvt. Ltd, DTA 004-002 Mahindra World City, PalriParsa, Village
in, Jaipur, Rajasthan ∙

Web www.frubon.com

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1
1
Production Halllayout of Ice Cream

Fruit
Crusher

Figure -9 production hall layout

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 Description

1. All dry and liquid ingredients are mixed here for preparation of ice-cream
mix. There are mainly 4 types of mix are prepared in fubon.
• Full fat mix having fat % of 10-11%
• Medium fat mix having fat % of 5-6%
• Low fat mix having fat % of below 4%
• Kulfi mix for kulfi products and fat% range is 8-10.5%

2. After mixing mixed ingredients are pasteurized at 75C for 20 mins. Tank
capacity 1000Land made up off stainless steel manufactured byATPL industry.

3. In kitchen roasting, grinding, of dry fruits and preparation of different sauces

and processing of different fruits are done to add them into ice cream.

4. After pasteurization mix is stored in to ageing tanks for at least 2 hours to

achieve desired texture and viscosity. There are 4 ageing tanks in frubon.
• Tank 1and2 have capacity of 2000L
• And tank 3 and 4 have capacity of 1000L
• Made up off stainless steel and manufactured by ATPL industry.

5. For making ice cream the mix from the ageing tank is taken at desired amount into
flavouring tanks and specific flavours and colours are added then mix is passed
through continuous freeze to achieve the proper texture of ice cream by over run.
• There are 3 flavouring tanks(FT) in frubon ice cream attached with 3
articular continuous freeze(CF).
• Capacity of tank1(1000L)
• Tank2(1000L)
• Tank3(1000L)

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 • Tank 1 is connected with CF1 having capacity of producing 200L icecream
per hour.
• Tank 2 is connected with CF2 having capacity of producing 300L icecream
per hour.
• Tank 3 is connected with CF3 having capacity of producing 600L icecream
per hour.

6. There are 2 manual candy machine which are operated manually to produce candy
varities like, prupop, kulfi,choco bon chunky, crunchy munchyctc.
Manual candy machine consists of main parts
I. Brine solution holding tank having capacity of holdingCaCl2 solution2000Lused
to harden the candy at aprox -25C.
II. To maintain the temperature at cooling unit.
III. A hardening chamber to harden ta candy again to achieve better texture

Figure - 10 manual candy machine

7. Cone filling and packaging machine is automatic machine which is connected with
continuous freeze with the help of flexible pipe so that icecreamcan be filled into
the cone properly and then it also covered by lead and mechanism of cone
machine controlled by air pumps. Having capacity of producing 3000 cone
icecreamper hour.

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 Figure -11 cone filling machine

8. Cup filling machine has the same working principle as cone machine
having capacity of producing 3000 cup ice-cream per hour.

Figure - 12 cupfilling machine

9. Auto candy machine consists of circular dye which is also controlled by air pumps
uses to produce candy ice creams. Like, kesarmalaikuldi, mini champ, all varities
of frulicksctc.

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 Figure -13 auto candy machine

10. In frubon there are 2 rapid cooling room called as blast room use to harden ta ice
creams rapidly to get prefect texture. Temperature maintained here is below -
25C.

11. There are 4 cold storage room in frubon to maintain the stock of ice cream
before sent to market. Temperature maintained here in range -15 to -18C.

Chapter #4

Products

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Ice creams

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1
 Kewra kulfi 60ml/50g
Pan Kulfi 60ml/50g
Punjabi TilaKulfi 60ml/50g
SahiRajwadiKulfi 60ml/50g

Frudolly Mango 60ml/50g

Strawberry 60ml/50g
Orange 60ml/50g

Frupop Butterscotch 15ml/10g

Ice Spice 15ml/10g

Choco Bon Mini Champ

40ml/27g
Bash
60ml/40g
Almond Truffle
60ml/40g
Fruit N Nut
60ml/40g
Chunky
60ml/40g

Fru Cone Pista passion

110ml/67g
Choco treat
110ml/67g
Mini choco
40ml/26g
treat
110ml/67g
Butterscotch
110ml/67g
Choco Vanila
110ml/67g
VanilaKesar
50ml/30g
Ripple
Cookie N Cream
110ml/67g
Carnival
110ml/67g
Strawberry
Delight

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1
Frudae Choco Almond 125ml/67g
Fudge 125ml/67g
Frubash 125ml/67g
Frusmash 125ml/67g
Black currant

Strawberry 125ml/67g
Frupple Frupple 125ml/67g
Chocolate Frupple 125ml/67g

Frujoy Vanilla 700ml/333g

Strawberry 700ml/333g
American Nuts 700ml/368g
Alphonso Mango 700ml/333g
Butterscotch 700ml/368g
Chocolate 700ml/333g
Kajukishmish 700ml/368g
KesarPista 700ml368g
VanilaChocochip 700ml/368g

Frublast Butterscotch
1.25l/657g
Chocochip
1.25l/657g
Choco Fudge
1.25l/657g
Fruit N Nut
1.25l/657g
Nepolitan
1.25l/657g
SahiRajbhog
1.25l/657g
Vanila
1.25l/657g
Strawbery
1.25l/657g

Casata Casata slices

150ml/85g

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MatkaKulfi MatkaKulfi 100ml/70g

Ice cream Black Fantasy 1l/525g

cake Golden Fantasy 1l/525g

Sweet Low fat ice 4l/2.1kg

Surprise cream(fat below
3%)
4l/2.1kg
Medium fat ice
cream(fat 4-6%)

4l/2.1kg
Ice cream(fat 9-
10.5%)

Table -2 products information

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Processing of cup ice cream

Mixing ingredients

( Milk,sugar, liquid glucose,SMP, stabilizer)

Pasteurization

(72°C for

20min)

Storing in ageing tanks

(at5°C for 2 hours at

least)

Passing into flavouring tank & Addition of flavour and colour

Passing through continuous freeze (at -4°C)

addition of fruits or chocochip thought fruit mixer

Filling and

packaging of cups in cup filling Manual filling and

pkg. and packaging machine
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Storage at cold room(Below -15°C)

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1
Processing of Frulicks

Mixing of ingredients (sugar, citric acid, liquid glucose, water)

Pasteurization (75°C for 15min& brix maintained at 25)

Transfer to holding tank (at 5 °C for 2 hours at least)

Ice candies are prepared from the syrup in auto candy machine

(At 3000 per hour speed)

Packaging

Storage (below -15°C)

Figure -15 different types of frulicks

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Frufles processing

Preparation of kulfi mix and ice cream mix and pasteurization

(at 75C for 20 min)

Holding in ageing tank

Roasting and grinding of dry fruits

Mixing of both kulfi and ice cream mix(at 6:4) ratio and addition of flavour and
colour in flavouring tank

Passing through continuous freeze (at -4C)

Collecting in containers and mixing of processed dry fruits

Moulding into desired moulds

Deeping into brine solution (at -25C)

De moulding( at 40C water for 3-5 sec)

Harding into hardening chember( at -20C for 30min)

Transfer into blast room (at -25C for at least 2 hours)

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 Packaging

Storage (at -15C)

Figure -16 different types of frufles

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Frudolly processing

Preparation of ice-cream mix and suger syrup

Pasteurization ( at 75°C for 20min)

Holding of syrup and ice cream mix in different ageing tank

(at 4°C for at least 2 hours)

Flavour and colour are added into flavouring tank

Then moulds are filled with syrup first and sucked by vacuum so that a thin layer
of syrup rmain in moulds

Icecream is filled in the moulds and ge harden (at -29°C)

With in few seconds they are de moulded and a thin layer or syrup remain out
side of the ice cream

Packaging

Storage (at -15°C)

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 Figure -17 different types of frudolly

Frupop Processing

Preparation and pasteurization of ice-cream mix(at 75C for 20min)

Preparation of dry fruits (dates,gulkand) for ice spice

Flavouring into flavouring tank

Collecting through continuous freeze in a container

&

Mixing of processed dry fruits ( for ice spice only)

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Moulding and deeping into brine solution)at _25C for 30min)

De mouldi(40C for 3_5sec)

Keep for hardening in cooling chamber (at -18C for 30min)

Coating with chocolate ( fupop butterscotch only)

Again hardening(at -18C)

Packaging

Storage (at -15C)

Figure - 18 different types of frupop

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Chocobon processing

Preparation of ice cream mix and pasteurization (at 75C for 20min)

Holding in ageing tank (at 4C for 2hours at least)

Addition of flavour in flavouring tank

Passing through continuous freeze and collecting in a container

Addition of dry fruits for different varieties

Pouring into moulds and keep in brine solution (at-25to-30C for 3min to 30mi )

De moulding (at 40C for 3-5 sec)

Hardening (-18C) (skipped for auto candy)

Chocolate coating(at 38C)

Again hardening (at-18C)

Packaging

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 Storage (at -15C)

Figure - 19 different types of chocobon

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Fru cone processing

Preparation of ice-cream mix and pasteurization (at 75C for 20 min)

Holding in ageing tank (for at least 2 hours)

Addition of flavour and colour in flavouring tank

Passing through continuous freeze (at -4C)

Addition od dry fruits thought fruit crusher

Filling into empty cones and lead closing in con machine

(At 3000 products per hour speed)

Packaging

Storage (at -15C)

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 Figure-20 different types of frucone

Frujoy processing

Preparation of ice-cream mix and pasteurization (at 75C for 20min)

Holding in ageing tank (at 4C for 2 hours at least)

Addition of flavours and colours in flavouring tank

Passing through continuous freeze (at -4C)

Addition of dry fruits

Manual filling and packaging

Storage (at -15C)

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 Figure - 21 Different types of frujoy

Cassata slices processing

Preparation of ice-cream mix and pasteurization (at 75C for 20min)

Holding in ageing tank (at 4C for at least 2 hours)

Addition of flavour and colour in flavouring tank

Passing through continuous freeze (at-4C)

Moulding of 1st layer through flexible pipe

Hardening (-25C for 24 hours)

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 Moulding of 2nd layer

Harding (-25C for 24 hours)

Moulding of 3rd layer

Harding (-25C for 24 hours)

De moulding (40C for 1 min)

Cutting into slices and packaging

Storage (-15C)

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 Figure- 22 casata sclice

Matka Kulfi processing

Preparation of Kulfi mix and pasteurization (75C for 20min)

Condensing till desire colour appears

Holding in ageing tank (4C for at least 2 hours)

Addition of flavour and colour in flavouring tank

Passing through continuous freeze (_4C)

Addition of dry fruits through fruit crusher

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Filling into matka manually and sealing by leads

Packaging

Storage (at-15C)

Figure - 23 matkakulfi

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Frudae processing

Preparation of ice-cream mix and pasteurization (75C for 20min)

Holding in ageing tank (4C for at least 2 hours)

Addition of flavour and colour in flavouring tank

Passing through continuous freeze (-4C)

Addition of dry fruits and sauce ( chocolate, crane berry, strawberry)

Filling into containers in cup filling machine

Manual sealing

Packaging

Storage at (-15C)

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 Figure - 24 different types of frudae

Frupple processing

Manufacturing steps of this product is same as frudae except there is no addition

of dry fruits in this product only sauce is add as toping.

Figure - 25 different types of frepple

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Frublast processing

Processing steps of Frublast is same as Frujoy only net quantity of Frublast is

different from Frujoy. It is of 1.25L and Frujoy is of 700ml.

Figure - 26 different types of frublast

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Sweet Surprise

This product is al same as Frujoy and Frublast only difference is it has net quantity
of 4L icecream and fat % is 4% or lower.

Figure -27 different types of sweet surprise

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Chapter #5
Q.C. LAB

Figure28- Q.c Lab

Q.C. LAB is a place from where the journey of ice cream begins, in this place
various tests were conduct on ice cream & ice cream mix to make sure that
consumer receive best quality ice cream.

A Quality Control (QC) lab in the ice cream industry is essential for ensuring that
the products meet the highest standards of safety, quality, and consistency. The
primary objective of a QC lab is to monitor and evaluate the entire production
process, from raw material procurement to the final product, ensuring compliance
with regulatory standards and internal quality benchmarks.

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 Key Functions of a QC Lab:

1. Raw Material Testing: o Ingredient Quality: Assessing the purity, freshness,

and suitability of ingredients such as milk, cream, sugars, emulsifiers, and stabilizers.
o Microbial Testing: Ensuring that raw materials are free from
harmful microorganisms that could spoil the product or pose health
risks.
2. In-Process Testing: o Mix Quality: Monitoring the composition and
consistency of the ice cream mix, including fat content, solids, and stabilizers.
o Pasteurization and Homogenization: Verifying that these processes
are effectively reducing microbial load and ensuring a uniform product.
3. Final Product Testing:
o Sensory Evaluation: Conducting taste tests to assess flavor, texture,
mouthfeel, and overall acceptability.
o Physicochemical Analysis: Measuring properties such as overrun
(air incorporation), melting resistance, viscosity, and hardness.
o Microbiological Testing: Ensuring the final product is free from pathogens and
meets microbial safety standards. o Shelf Life Studies: Evaluating the
product’s stability and quality over time under various storage conditions.
4. Packaging and Storage: o Packaging Integrity: Checking for proper
sealing, labeling, and packaging materials that protect the product.
o Storage Conditions: Monitoring the storage environment to ensure it is
optimal for maintaining product quality.
5. Regulatory Compliance:
o Ensuring that the ice cream meets local and international food safety
standards and regulations.

o Documentation and traceability to provide records for audits and

quality certifications.

Importance of QC Labs:

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• Product Consistency: Ensures that each batch of ice cream meets the same
quality standards, enhancing consumer trust and brand loyalty.
• Safety Assurance: Detects and mitigates potential health risks,
protecting consumers and the brand’s reputation.
• Process Optimization: Identifies areas for improvement in the production
process, leading to better efficiency and cost-effectiveness.
• Innovation Support: Assists in the development of new flavors and
formulations by providing detailed analytical data.

Overall, a QC lab is indispensable for maintaining the quality and safety of ice
cream products, supporting continuous improvement, and driving innovation
within the industry.

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Gerber centrifuge Burette

Weighing balance Autoclave

B4 Cup viscometer

Figure 29- Q.C lab equipements-

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 Chapter #6: Project

Title: “Effects of Fat and Stabilizers on the physicochemical and functional properties
of ice cream”

1) Introduction to the project:

Ice cream is a widely popular frozen dessert, valued for its creamy texture, rich
flavor, and refreshing properties. Its popular among all age groups and cultures,
making it a important product in the dairy industry. The quality of ice cream is
determined by the interaction between its ingredients and processing methods,
which collectively influence its physicochemical and functional properties.

Ice cream generally contains seven categories of ingredients: milk fat, milk
solidsnot-fat (the lactose, proteins, minerals, water-soluble vitamins, enzymes,
and some minor constituents), sweeteners, stabilizers, emulsifiers, water, and
flavours. In this post, we'll be looking at the role of fat in ice cream.

Among the key ingredients, fat and stabilizers play important roles in defining
the texture, consistency, and overall sensory experience of the product.

Fat contributes to the creaminess, smooth mouthfeel, and flavour release in ice
cream. It affects the overrun (the amount of air incorporated), melting behaviour,
and thermal stability. Different fat levels can result in variations in these
properties, thereby affecting the consumer preference and product performance
during storage and consumption.

Stabilizers, on the other hand, are hydrocolloids that enhance the viscosity of the
ice cream mix and prevent the formation of large ice crystals. They play a
crucial

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 role in maintaining the structural integrity and texture of ice cream, especially
during storage and temperature fluctuations. Commonly used stabilizers include
guar gum, carrageenan, and xanthan gum, each imparting unique textural and
stabilizing effects.

Understanding the synergistic effects of fat and stabilizers on the

physicochemical and functional properties of ice cream is essential for optimizing
product formulations. This study aims to systematically explore how varying
levels of fat and different stabilizers influence key quality attributes such as
texture, melting rate, overrun, and sensory characteristics. By doing so, it seeks to
provide insights that can help in developing ice cream with superior quality and
consumer appeal, thereby enhancing its market competitiveness.

Importance and objectives of the project:

Importance-

Understanding the effect of fat and stabilizers on the physicochemical and

functional properties of ice cream is crucial for several reasons:

1. Product Quality and Consistency: Fat and stabilizers are key components that
determine the texture, mouthfeel, and stability of ice cream. By optimizing
these ingredients, manufacturers can consistently produce high-quality ice
cream with desirable sensory properties, such as creaminess, smoothness, and
flavor.
2. Consumer Satisfaction: Consumer preferences for ice cream are largely
influenced by its texture and taste. A well-balanced formulation that
incorporates the right levels of fat and stabilizers can enhance the overall eating
experience, leading to increased consumer satisfaction and brand loyalty.
3. Shelf Life and Storage Stability: Stabilizers help to maintain the structural
integrity of ice cream by preventing ice crystal growth and phase separation during
storage. This extends the shelf life of the product, ensuring that it remains
enjoyable for consumers over a longer period.

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4. Nutritional Considerations: With growing consumer awareness about health and
nutrition, there is a demand for lower-fat ice cream options that do not
compromise on quality. Understanding how to effectively use stabilizers to
maintain desirable properties in low-fat ice creams can help manufacturers meet
this demand.
5. Cost Efficiency: Optimizing the use of fat and stabilizers can lead to cost
savings in production. By finding the right balance, manufacturers can reduce the
amount of expensive fat without sacrificing quality, thereby improving the
economic viability of their products.
6. Innovation and Competitive Advantage: Knowledge of the effects of fat and
stabilizers allows for innovation in product development. Manufacturers can
create new and unique ice cream varieties, such as those with novel textures or
flavors, giving them a competitive edge in the market.
7. Regulatory Compliance: Different markets have varying regulations regarding
the composition of ice cream. A thorough understanding of how fat and stabilizers
affect the product can help manufacturers ensure compliance with these regulations
while still producing a high-quality product.

In summary, studying the effects of fat and stabilizers on ice cream is essential for
producing a product that meets consumer expectations, maintains quality over
time, and remains economically feasible for manufacturers. This knowledge
supports the development of innovative, satisfying, and compliant ice cream
products in an increasingly competitive market.

Objectives-

To Investigate the Impact of Fat Content:

• Evaluate the effects of varying fat levels (low, medium, high) on the
physicochemical properties of ice cream, including viscosity, overrun,
and hardness.

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• Determine how fat content influences the sensory characteristics such
as creaminess, smoothness, and mouthfeel.

To Explore Interactions Between Fat and Stabilizers:

• Investigate the synergistic or antagonistic effects between fat content and

stabilizers on the overall quality of ice cream.
• Identify the optimal combination of fat levels and stabilizers to achieve
desirable physicochemical and sensory properties.

To Conduct Sensory Evaluation:

• Perform sensory evaluations to assess consumer preferences regarding

different formulations of ice cream with varying fat and stabilizer contents.
• Correlate sensory data with physicochemical measurements to
understand consumer perception of quality.

To Provide Recommendations for Industry:

o Offer practical recommendations for the dairy industry on optimizing ice

cream formulations to improve product quality and consumer satisfaction.
o Create guidelines for selecting appropriate fat levels and stabilizers to
achieve specific functional and sensory attributes in ice cream products.

To Assess the Role of Different Stabilizer content:

Examine the effects of various stabilizers content on the functional properties of ice
cream, focusing on texture, consistency, and melting behaviour.

Review of existing literatures:

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Literature no. 1: Evaluating the effect of fat content on the properties of
vanilla ice cream using principal component analysis
Author’s name- Fatemeh Sadat Mostafavi Received: 14 January 2019 / Accepted: 21
May 2019 / Published online: 27
May 2019
DOI:10.1007/s11694-019-00162-z

Abstract- In the current study, the effect of fat content on the physicochemical
and sensory properties of vanilla ice cream was investigated using principal
component analysis (PCA) and quantitative descriptive analysis (QDA). For this
purpose low fat, light, reduced fat and full fat ice creams were produced using 2,
5, 7.5 and 10% milk fat respectively. According to the results, reduction of fat in
ice cream contributed to a significant decrease in total solid (TS) and caloric
value of the samples and increased their protein content and pH value
significantly (p < 0.05). The QDA of sensory properties demonstrated that the
decreased fat samples had lower viscosity, mouth coating, smoothness and
firmness and higher melting rate and coldness sensations in comparison with the
full fat ice cream. PCA technique was used to simplify discussion of the obtained
results. Two principal components (PC) named as PC1 and PC2 described a total
of 96.12% of the variation of the initial variables. PC1 was primarily related to
the values of coldness, viscosity, mouth coating, smoothness, firmness, melting
rate, overall acceptance, pH, TS, protein and calorie; while PC2 was related to the
acidity of the samples. Distribution pattern of the studied attributes showed that
the melting rate and coldness sensation discovered in opposite quadrants of other
sensory attributes; while, close relations were observed between the smoothness
and TS, viscosity and mouth coating and also between the pH value, protein
content and melting rate of the ice cream. A comparison between the correlation
results of the fat content with the sensory attributes showed that the viscosity of
the ice cream samples was more dramatically affected by the fat reduction.
Therefore, it is suggested to use a type of fat replacer which can effectively
improve the viscosity of low fat ice cream products.

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Literature no. 2- Application and Functions of Stabilizers in Ice Cream
Author’s name- Maryam Bahramparvar & Mostafa Mazaheri
Tehrani Published online: 03 Mar 2011
DOI: 10.1080/87559129.2011.563399

Abstract- Ice cream as a complex food consists of small air cells dispersed in a
partially frozen, continuous aqueous phase. Its desired quality is achieved by both
proper processing and formulation. Stabilizers are substances that, despite their
low usage level in ice cream mix, have very important functions, such as increase
in viscosity of ice cream mix, aeration improvement, cryoprotection, and control
of meltdown. Various materials, including both commercial and local gums, have
been used as stabilizers. In this review, types of stabilizers, their functions, and
limitations on excessive use of stabilizers in ice cream are discussed.

Literature no. 3- The Effects of Fat Structures and Ice Cream Mix Viscosity
on Physical and Sensory Properties of Ice Cream

First published: 20 June 2017

Author’s name- Julia Amador, Rich Hartel, Scott Rankin
DOI: 10.1111/1750-3841.13780

Abstract- The purpose of this work was to investigate iciness perception and
other sensory textural attributes of ice cream due to ice and fat structures and mix
viscosity. Two studies were carried out varying processing conditions and mix
formulation. In the 1st study, ice creams were collected at −3, −5, and −7.5 °C
draw temperatures. These ice creams contained 0%, 0.1%, or 0.2% emulsifier, an
80:20 blend of mono- and diglycerides: polysorbate 80. In the 2nd study, ice
creams were collected at −3 °C draw temperature and contained 0%, 0.2%, or
0.4% stabilizer, a blend of guar gum, locust bean gum, and carrageenan. Multiple
linear regressions were used to determine relationships between ice crystal size,
destabilized fat, and sensory iciness. In the ice and fat structure study, an inverse

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correlation was found between fat destabilization and sensory iciness. Ice creams
with no difference in ice crystal size were perceived to be less icy with increasing
amounts of destabilized fat. Destabilized fat correlated inversely with dripthrough
rate and sensory greasiness. In the ice cream mix viscosity study, an inverse
correlation was found between mix viscosity and sensory iciness. Ice creams with
no difference in ice crystal size were perceived to be less icy when formulated
with higher mix viscosity. A positive correlation was found between mix
viscosity and sensory greasiness. These results indicate that fat structures and mix
viscosity have significant effects on ice cream microstructure and sensory texture
including the reduction of iciness perception.

Literature no. 4- Effect of fat content on the physical properties and consumer
acceptability of vanilla ice cream

Author’s name- M Laura Rolon , Alyssa J Bakke , John N Coupland , John

E Hayes , Robert F Roberts

Published: April 26, 2017

PMID: 28456409

DOI: 10.3168/jds.2016-12379

Abstract- Ice cream is a complex food matrix that contains multiple physical
phases. Removal of 1 ingredient may affect not only its physical properties but
also multiple sensory characteristics that may or may not be important to
consumers. Fat not only contributes to texture, mouth feel, and flavor, but also
serves as a structural element. We evaluated the effect of replacing fat with
maltodextrin (MD) on select physical properties of ice cream and on consumer
acceptability. Vanilla ice creams were formulated to contain 6, 8, 10, 12, and 14%
fat, and the difference was made up with 8, 6, 4, 2, and 0% maltodextrin,
respectively, to balance the mix. Physical characterization included measurements

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 of overrun, apparent viscosity, fat particle size, fat destabilization, hardness, and
melting rate. A series of sensory tests were conducted to measure liking and the
intensity of various attributes. Tests were also conducted after 19 weeks of
storage at -18°C to assess changes in acceptance due to prolonged storage at
unfavorable temperatures. Then, discrimination tests were performed to
determine which differences in fat content were detectable by consumers. Mix
viscosity decreased with increasing fat content and decreasing maltodextrin
content. Fat particle size and fat destabilization significantly increased with
increasing fat content.
However, acceptability did not differ significantly across the samples for fresh or
stored ice cream. Following storage, ice creams with 6, 12, and 14% fat did not
differ in acceptability compared with fresh ice cream. However, the 8% fat, 6%
MD and 10% fat, 4% MD ice creams showed a significant drop in acceptance after
storage relative to fresh ice cream at the same fat content. Consumers were unable
to detect a difference of 2 percentage points in fat level between 6 and 12% fat.
They were able to detect a difference of 4 percentage points for ice creams with
6% versus 10%, but not for those with 8% versus 12% fat. Removing fat and
replacing it with maltodextrin caused minimal changes in physical properties in
ice cream and mix and did not change consumer acceptability for either fresh or
stored ice cream.

2) Materials and Methods-

Raw materials-

The raw materials used for preparing an ice cream mix are crucial for determining
the final product's quality, texture, and flavor. Here is a list of common raw
materials used in ice cream mix:

1) Milk- Milk is a fundamental ingredient in ice cream mix due to its unique
combination of properties that contribute to the overall quality and
characteristics

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 of the final product. Especially whole milk, contains fat, which is essential for
providing the creamy texture and smooth mouthfeel that is characteristic of ice
cream. The fat in milk helps to create a rich, indulgent texture by coating the
tongue and adding body to the ice cream. Milk proteins, primarily casein and
whey proteins, contribute to the structure and stability of the ice cream mix.
These proteins help to emulsify the fat and water phases, creating a stable
emulsion that prevents separation. Milk imparts a subtle, natural dairy flavor that
forms the base of ice cream. This mild flavor enhances the overall taste and
complements added flavors like vanilla, chocolate, or fruit. Milk's neutral flavor
makes it an ideal base for a wide variety of flavorings and mix-ins. Whether it’s
chocolate, fruit, nuts, or syrups, milk serves as a versatile foundation that can be
easily adapted to different recipes and tastes.
2) Skim Milk Powder(SMP)- Skim milk powder is primarily used to boost the milk
solids-not-fat (SNF) content in the ice cream mix. SNF includes proteins,
lactose, minerals, and other components of milk, excluding fat. SNF consist of
proteins, lactose and mineral salts derived from whole milk, skim milk,
condensed milk, milk powders and/or whey powder. In addition to its high
nutritional value, SNF helps to stabilize the structure of ice cream due to its
water-binding and emulsifying effect. The same effect also has a positive
influence on air distribution in the ice cream during the freezing process, leading
to improved body and creaminess. SMP is a rich source of dairy proteins, which
are essential for nutritional balance and contribute to the overall protein content
of the ice

cream. SMP is a cost-effective way to increase the solids content without adding
more fat, which can be more expensive. Unlike fresh milk, SMP has a longer shelf
life and can be stored without refrigeration, reducing storage and transportation
costs. The lactose in SMP acts as a natural sweetener, enhancing the overall flavor
profile of the ice cream without adding extra sugars.
3) Butter- Butter plays a significant role in ice cream formulation, primarily
because of its fat content and its impact on the texture, flavor, and overall quality
of the ice cream. Butter is a rich source of milk fat, which is essential for creating
the creamy, smooth texture that is characteristic of high-quality ice cream. The fat
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globules in butter help to coat the tongue, providing a rich and indulgent mouthfeel.
The fat in butter contributes to the body and stability of ice cream, preventing it
from becoming too icy or grainy. This helps in achieving a desirable, uniform
texture. Butter adds a rich, buttery flavor to ice cream, enhancing its overall taste
profile. This flavor is particularly desirable in certain types of ice cream, such as
those with caramel, vanilla, or nut flavors. Butter is a valuable ingredient in ice
cream production due to its multiple functional roles. It enhances the creaminess,
texture, and flavor of the ice cream while also contributing to its stability, air
incorporation, and shelf life. By understanding and optimizing the use of butter in
ice cream formulations, manufacturers can produce a high-quality product that
meets consumer expectations for taste and texture.
4) Sweetners (sucrose/glucose)- Sugar is added to increase the solids content of the
ice cream and give it the level of sweetness consumers prefer. Ice cream mix
normally contains between 12 to 20% sugar. Sugar is the common description for
the saccharides, including the monosaccharides (i.e. glucose/dextrose and
fructose), disaccharides (i.e. sucrose and lactose (milk sugar)) and starch
derivates (i.e. glucose syrup, glucose/fructose syrup and high fructose syrup).
The consistency of the ice cream can also be adjusted by selecting different
types of sugar. This makes it possible to produce ice cream that is easy to scoop.
In the production of sugar-free ice cream, sweeteners are used to replace sugar.
Aspartame, acesulfame K and sucralose are the most commonly used sweeteners in
ice cream.
Glucose syrup has a significant role to play in ice creams; it prevents
crystallization of Ice creams, adds a smooth texture and prevents it from getting
melted soon. By preventing crystallization of sucrose it offers a soft mouthful,
creamy touch and a homogenous sweetness to the ice cream. Glucose syrup does
not add any undesirable taste and liquid glucose substitute is excellent
replacement for expensive non-fat milk solids too.
5) Stabilizers- A stabilizer is a substance that has the ability to bind water when
dispersed in a liquid phase. This is called hydration and means the stabilizer
forms a matrix that prevents the water molecules from moving freely. Most of the

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 stabilizers utilized for ice cream are large molecules derived from seeds, wood or
algae/seaweed. Stabilizers are used in ice cream production to increase the
viscosity of the mix and create body and texture. They also controls the growth of
ice crystals and improve melting resistance. The main purpose of adding
stabilizers to ice cream is to prevent the product shrinkage and moisture
migration to the package by stabilizing air bubbles. Besides, stabilizers help to
hold the flavoring particles in the mix and ensure good flavor release. Examples
of some commonly used stabilizers are-
Guar Gum: Prevents ice crystal formation and improves body and texture.
Carrageenan: Derived from seaweed, it stabilizes the ice cream mix by interacting
with milk proteins.
Xanthan Gum: Provides viscosity and stabilizes the ice cream structure.
Locust Bean Gum: Enhances creaminess and prevents syneresis (water
separation).
6) Emulsifiers- Emulsifiers are substances that assist emulsification by reducing
surface tension between two phases. There exists several different emulsifier
types utilized in ice cream production, but the far most dominant and probably
most effective emulsifier is the mono-/diglyceride of fatty acids. The
mono-/diglyceride is often derived from a a vegetable fat (triglyceride) where
fatty acid chains have been removed, creating a molecule that has a lipophilic end
(fat loving) and a hydrophilic part (water loving). The mono-/diglyceride has two
main functions during ice cream processing, where it assists the dairy protein
displacement from the fat surface membrane, in order to improve the churning
during the freezing process. The mono-/diglycerides also seed the crystallization
of fat, which is essential for avoiding overchurning of the fat during the freezing
process. Egg yolk is a well-known emulsifier, but is expensive and less effective
than the most commonly used types. The most common emulsifiers used at the
modern factories are mono- and di-glycerides (DMG). They are highly helpful in
making ice cream smoother and thicker with a better mouthfeel and enhanced
meltdown capabilities. This is possible because DMG reshapes the fat structure
preventing it from separating. It also controls the air distribution in the mix.

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7) Maltodextrin- Maltodextrin is a common ingredient used in the preparation of
ice cream mix due to its versatile functional properties. Maltodextrin acts as a
bulking agent, increasing the volume of the ice cream mix without significantly
altering its flavor or sweetness. This is particularly useful in creating a desirable
texture and body. Maltodextrin helps to improve the mouthfeel of ice cream by
contributing to a smooth and creamy texture. It helps to reduce the perception of
iciness, making the ice cream feel more luxurious and velvety on the palate.
Maltodextrin is relatively inexpensive compared to other ingredients that improve
texture and stability. Its use can be economically beneficial for large-scale ice
cream production. Maltodextrin is used in ice cream mix for its ability to enhance
texture, stabilize the product, control ice crystal formation, and improve the
overall quality of the ice cream. Its multifunctional properties make it an
invaluable ingredient in the formulation of both traditional and reduced-fat ice
creams, ensuring that the final product meets consumer expectations for
creaminess, smoothness, and flavour.
8) Thickners- Thickeners play a crucial role in the formulation and quality of ice
cream. They are essential for creating the desired texture, improving stability, and
enhancing the overall sensory experience. Thickeners contribute to a creamier
and smoother texture by increasing the viscosity of the ice cream mix. This helps
to create a rich mouthfeel that is characteristic of high-quality ice cream.
Thickeners improve the overall mouthfeel, making the ice cream feel more
substantial and luxurious on the palate. By increasing the viscosity of the ice
cream mix, thickeners help to achieve the desired consistency and improve the
handling characteristics during production and storage. Thickeners help to
prevent syneresis (the separation of liquid from the mix), ensuring a consistent
texture throughout the shelf life of the ice cream. Thickeners are essential
components in ice cream production, offering numerous benefits that enhance the
texture, stability, and overall quality of the final product. By preventing ice
crystal formation, maintaining consistency, and improving the sensory attributes,
thickeners ensure that ice cream remains smooth, creamy, and enjoyable from the
first scoop to the last. Their versatile and cost-effective nature makes them

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 indispensable in the formulation of both traditional and innovative ice cream
products.
9) Water- Water acts as a solvent for sugars, salts, stabilizers, and other soluble
ingredients. This helps to create a uniform mixture and ensures that these
components are evenly distributed throughout the ice cream mix. Stabilizers and
emulsifiers require water to hydrate properly and perform their functions
effectively. Hydration helps in forming a stable emulsion and improving the
texture of the ice cream. Water freezes to form ice crystals, which are essential
for the structure of ice cream. The size and distribution of these ice crystals are
critical for the texture. Small, uniform ice crystals contribute to a smooth and
creamy texture, while large crystals can make the ice cream grainy. Water is a
fundamental component of ice cream, essential for dissolving ingredients,
controlling texture, regulating temperature, and contributing to the overall
structure and sensory qualities of the final product. Managing the water content
and its interactions with other ingredients is crucial for producing high-quality ice
cream with desirable texture, flavor, and stability.

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 Formulations-

1) For 3.0% fat ice cream

Mix with 3.0% fat and 0.69% stabilizer

Ingredients Quantity in
percentage

Milk(Fat3.75%;SNF- 63.6%
8.32)

SMP 5.50%
Sugar 16.4%
Butter 0.75%
Liquid glucose 2.0%

Stabiliser 0.69%

Maltodextrin 3.0%
Thickener 0.69%
Water 7.37%
2) For 5.5% fat ice cream
Mix with 5.5%fat and 0.6% stabilizer

Ingredients Quantity in
percentage

Milk(Fat3.20%;SNF- 63.63%
8.18)

SMP 5.59%
Sugar 16.90%

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 Butter 4.22%

Liquid glucose 0.0%

Stabiliser 0.6%

Maltodextrin 3.90%
Thickener 0.6%

Water 4.56%

3) For 11.0% fat ice cream

Mix with 11.0% fat and 0.54% stabilizer

Ingredients Quantity in
percentage

Milk(Fat2.90%;SNF- 63.63%
8.15)

SMP 5.67%

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 Sugar 14.54%

Butter 11.18%

Liquid glucose 1.81%

Stabiliser 0.54%

Maltodextrin 0.0%

Thickener 0.0%

Water 2.63%

NOTE:- Stabilizers - INS 407(Carrageenan) ,INS 412(Guar Gum), 1NS

491(Sorbitan monostearate).

Emulsifiers- INS 471(Glyceryl monostearate).

Thickeners- INS 1440(Modified Starch).

Process Flow Chart:-

1) Preparation of mix

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1
2) Preparation of ice cream

Processes used-

1) Weighing &Mixing of ingredients

Figure30-Mixing vat
 The most important process while producing ice-cream for the determination of
the following:

‣composition of the mix

‣amount of ice-cream to be made

‣composition of ingredients to be used

All the ingredients (like Milk, Butter, SMP, Sugar, Stabilizer and Emulsifier)
were weighed as per mix calculations and put in the steam jacketed blender for
dissolving and blending. Blending is the initial step for operation of the ice-cream
manufacturing process. In this step, all the ingredients are added to milk at
different temperatures as per the process.

Pearson square method is generally used for the calculation of product mix. The
other important consideration is a correct total solid to water ratio. If the ratio is
too high, it results in sandiness and rough texture of the ice cream. If the ratio is
too low, it results in the ice-cream having glassy or icy texture along with weak
body.

2) Pre heating:

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 Figure31-Pre heating tank

The objective of pre-heating the mix is to increase the temperature of the mix for
appropriate mixing of all ingredients. It helps to avoid lumpiness of dry
ingredients. It also increases the efficiency of pasteurization and homogenization
of the mix. Usually, pre-heating is conducted at a temperature between 20 to
25°C.

3) Homogenization

Figure32-Homogenizer

The main purpose of homogenization is to make a permanent and uniform

suspension of fat. This is done by reducing the size of the fat globule to a very
small diameter preferably not more than 2 microns. Homogenization of mix is
carried out at 63–77°C with the help of a 2-stage homogenizer (pressure at the 1st
stage: 2500 psi and at the 2nd stage: 500 psi respectively) The benefits of the
homogenization are:

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 ‣It Prevents fat separation during ageing

‣It Produces more uniform ice-cream with a smoother texture

‣It Improves whipping ability

‣It Shortens ageing period

‣It Decreases the risk of churning occurring in the freezer

‣It Helps in the process of stabilization

4) Pasteurization

Figure33-Continuous pasteurizer

An ice-cream mix may contain various types of microorganisms, especially

pathogens. Hence, it is important to pasteurize the ice-cream mix. The general
standards for pasteurizing the ice-cream mix are:

‣ LTLT method – 68.5º C for not less than 30 minutes

‣ HTST method – 80º C for not less than 25 seconds

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 A continuous type pasteurization method is employed in most of the dairies where
the mix is pasteurized at 82 to 86º C for 25 seconds. The advantages of
pasteurization are:

‣ It Renders the mix completely free of pathogenic bacteria, without

disturbing the nutritive and acceptable quality of the mix

‣ Dissolves and helps to blend the ingredients of the mix

‣ It Improves the flavour of the mix

‣ It Improves the ice-cream’s keeping quality

‣ It Helps to maintain uniformity in production

5) Cooling And Ageing-

Figure34-Aging Tanks

After heating/pasteurizing, the mix is sent to the cooling section. In this section,
temperature is reduced from 82° C/84° C to 6 °C. This is done to facilitate the
process of ageing the ice-cream mix. Ageing refers to the process of holding the
mix at a low temperature for a definite time before freezing. The ageing
temperature has to be maintained at 5° C. The ageing time under average
commercial conditions may be 3-4 hours

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 Ageing is used to:

• Improve body and texture of ice-cream

• Improve whipping capacity of mix

• Increase maximum overrun

• Increase resistance to melting

6) Freezing and Overrun

After ageing, the mix is ready for freezing. Freezing is important as it helps to
ensure the quality, palatability, and satisfactory overrun in the finished product.
The freezing time for continuous ice-cream freezers is 24 seconds for
temperatures between -6 to -5 °C. The function of the freezing process is to
freeze a portion of the water of the mix and to incorporate air into the mix. This
process takes less than 2 minutes.

This is done by:

• Lowering the temperature of the mix from ageing temperature to the

freezing point

• Freezing a portion of the water in the mix

• Incorporating air into the mix

• Cooling ice-cream from the temperature at which it is drawn from the freezer

• Hardening the ice-cream till room temperature while sensible heat is

being removed and before any ice crystal formed

Overrun is the volume of ice-cream obtained in excess of the volume of the mix. It
is expressed in percentage. This increased volume is due to the air incorporated
during the freezing into the ice-cream. It mainly depends upon:
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 • The composition of the mix

• The method of processing

Overrun gives the body of ice-cream mix proper texture and palatability necessary
to a good quality product. Too much of overrun produces snowy, fluffy,
unpalatable ice-cream. Too little overrun produces soggy, heavy products.

7) Filling and Packaging-

Figure35-Packaging of ice creams

After drawing the ice-cream from the freezer, it is usually collected in

containers to give it desired shape or size for convenient handling during the
hardening and marketing processes. The main requirements for packaging of
ice-cream are:

• Protection against contamination

• Attractive appearance

• Ease of opening and re-closure

• Ease of disposal

• Protection against moisture loss

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 • Ability to withstand temperature fluctuation The packaging materials generally

used are:

• Wax coated fibre board cartons

• Polythene wax blends for protection against moisture and oxygen

• Plastic cylinder containers

• Polycups

• Sticks

• Bars

8) Hardening and Storage

For hardening, ice-cream is put into trays and placed in hardening tunnels. At this
point, ice-cream has a semi-fluid consistency and is not stiff enough to hold its
shape. During the process of hardening, ice- ream is brought to a temperature
between -20 to -35ºC or below. In the freezer, quick hardening is desirable since
slow hardening favours large ice crystals and coarseness.

The factors affecting hardening time are:

‣Size and shape of the ice-cream package

‣Speed of air circulation

‣Temperature of cooling air

‣ Sections of hardening room

‣Temperature of ice-cream drawn from the freezer

‣Composition of mix
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‣% overrun in the ice-cream being hardened

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Figure36-Storage of ice creams in cold room Processing Parameters-

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 For pasteurization & homogenization-

For 11.0% mix

Time Temp. of mix Pasteurization Homogenizer Homogenizer Cooling
before temp. Pressure-1 Pressure-1 temp.
pasteurization (In Bar) (In Bar)
9:05AM 67.5ºC 78.5ºC 180 35 4.0ºC
For 5.5% mix
Time Temp. of Pasteurization Homogenizer Homogenizer Cooling
mix before temp. Pressure-1 Pressure-1 temp.
pasteurization (In Bar) (In Bar)
12:10pm 65.1ºC 80.1ºC 186 35 4.0ºC
For 3.0% mix
Time Temp. of Pasteurization Homogenizer Homogenizer Cooling
mix temp. Pressure-1 Pressure-1 temp.
before (In Bar) (In Bar)
pasteurization
10:05am 65.1ºC 80.2ºC 183 35 4.0ºC

Quality tests used for assessing the quality of product-

1) Total solids-

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Figure37- TS Determination

Materials required – T.S. plates , weighing balance, Hot air oven, water bath

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CALCULATION-
(Wt.of empty dish- Wt. of dish after drying)
T.S.= -------------------------------------- * 100
Wt. of sample taken

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2) Acidity-

Figure 38-Titration

• Materials required- conical flask,1% phenolphthalein ind. ,0.1N NaOH

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CALCULATION-
(Vol. of NaOH used(ml)*0.1N*0.9)
Acidity= *10
Wt. of sample taken(gm)

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3) Fat % ( By Gerber’s Method )-

Figure39-Fat Analysis

Materials required- Butyrometer, Gerber Acid, Gerber Centrifuge, Rubber

stopper

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CALCULATION-
For 10% butyrometer-

(Reading * 11.25)
Fat%=

(Wt. of sample taken)

For 20% butyrometer-

(Reading * 5)
Fat%=

(Wt. of sample
For 40% butyrometer-

taken)
Fat%=

(Reading * 3)

(Wt. of sample

taken)
4) Viscosity-Materials required-B4cup viscometer, waterbath, Thermometer

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 Figure40-B4 cup viscometer

5) Protien content by Kjedahl Method-

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CALCULATION-

( (B-S)*6.38*14*0.1N )

Protein%= *100

Wt. of sample(gm)*1000

Where,

B=BLANK

S=STANDARD

5) Results-

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 Effect of Fat Content & Stabilizer on Physicochemical Properties

1) Composition
PARMETER ICE CREAM MIX F
S FAT FAT FAT
3.0 5.5 11.0
%;S %;S %S
TB TB TB
0.69 0.6 0.54
T.S. 34.6 37.9 39.5
1% 4% 3%
FAT% 3.1 5.83 11.3
% % %
ACIDITY 0.14 0.15 0.16
4 3 2
PROTEIN 3.56 3.74 3.91
HOMOGENI 81.0 78.2 76.4
ZATION 6% 6% 8%
EFFICIENC
Y
From the above table we can observe that the fat & STAIBILIZER in ice
cream is also affecting its T.S. value and homogenization efficiency.

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1) Effect on T.S.-

EFFECT OF FAT AND STABILIZER ON

40.00% T.S.
39.00%

38.00%

37.00%

36.00%

35.00%

34.00%

33.00%

32.00%
3.00% 5.50% 11.00%

T.S. value

From the above graph we can see that as the value of fat in ice cream
increasing its T.S. value is also increasing. So we can say that fat value is
directly proportional to T.S. value

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2) Homogenization Efficiency(H.E.)-

EFFECT OF FAT & STABILIZER ON

H.E.

81.06%

78.26%

6.48%

3.00% 5.50% 11.00%

From the above graph we can see that as the fat % of mix is increasing its
efficiency of homogenization is decreasing. This phenomena is happening
because as the fat % is increasing its fat destabilization is also increasing
hence resulting in decrease pf HE Value.

2) VISCOSITY

The measured viscosities for the ice cream mixes with different fat contents are
summarized in the table below:

Viscosity at 3.0% 5.5% 11.0%

0 Hour 66 sec 49 sec 44 sec

4 Hour 71 sec 53 sec 45 sec

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 24 Hour 76 sec 60 sec 51 sec

effect of fat & stabilizer on viscosity

80

70

60

50

40

30

20

10

3.00% 5.50% 11.00%

From given data we can see that ice cream with lowest fat % have highest
viscosity and ice cream with highest fat % have lowest viscosity. It is
because of the stabilizer content in lowest fat mix is highest and stabilizers
also act as a thickening agent which causes increase in the viscosity

3) Overrun-

Overrun is a critical parameter in ice cream production that refers to the amount
of air incorporated into the ice cream mix during the freezing process. It is
expressed as a percentage and indicates how much the volume of the ice cream
has increased compared to the original volume of the mix. Overrun affects the
texture, mouthfeel, and overall quality of the ice cream. High overrun results in a
lighter, softer ice cream, while low overrun results in a denser product.

Overrun is calculated using the following formula:

Overrun (%) = ( (Weight of Mix−Weight of Ice Cream

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)/Weight of Ice Cream)×100

The measured overrun for the ice cream mixes with different fat contents are
summarized in the table below:

3.0%; 5.5%; 11.0%;

0.69 0.60 0.54

Over 65% 127% 140%

run

From above table we can see that as fat content is increasing overrun of ice cream
is also increasing it is because fat helps in stabilizing the air bubbles in the ice
cream mix, which can lead to a higher overrun. So with lower fat levels, there is
less stabilization of air bubbles, which can result in lower overrun.

Effect of Fat Content & Stabilizer on Organoleptic Properties of Ice cream

Sensory Evaluation- I conduct a sensory analysis of vanilla flavoured ice creams

made from 3.0% mix, 5.5% mix & 11.0% mix

Sample A – Fat-3.0%; Stabilizer- 0.69%

Sample B – Fat-5.5%; Stabilizer- 0.60%

Sample C – Fat-11.0%; Stabilizer-

0.54%

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 Sensory Analysis of Sample-A

0
Panellist 1 Panellist 2 Panellist 3 Panellist 4 Panellist 5

Appearance Taste Odour Mouthfeel

Sensory Analysis of Sample-B

6.8

6.6

6.4

6.2

5.8

5.6

5.4
PANELLIST 1 PANELLIST 2 PANELLIST 3 PANELLIST 4 PANELLIST 5

Appearance Taste Odour Mouth Feel

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 Sensory Analysis of Sample-C

6.8

6.6

6.4

6.2

5.8

5.6

5.4
PANELLIT 1 PANELLIT 2 PANELLIT 3 PANELLIT 4 PANELLIT 5

Appearance Taste Odour Mouth Feel

Discussion

The results indicate that both fat and stabilizers significantly influence the
physicochemical and functional properties of ice cream. Higher fat content
enhances Total solids, smoothness, and Over run, while stabilizers improve
viscosity, and Homogenization Efficiency . The combination of 11% fat with
0.54% stabilizer or 5.5% fat with 0.60% stabilizer yields ice creams with optimal
physicochemical properties and superior sensory attributes.

6) Conclusion

The comprehensive study on the effect of fat and stabilizers on the

physicochemical and functional properties of ice cream provides profound
insights into the formulation of this popular dairy product. The interplay between
fat content and stabilizers has a significant impact on key quality attributes such
as texture, meviscosity, overrun, and sensory characteristics, which ultimately
determine consumer satisfaction and market success.

Fat Content

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Fat is a critical component in ice cream, contributing to its creamy texture,
smooth mouthfeel, and rich flavor. Our findings indicate that higher fat levels
enhance these sensory attributes by creating a denser network of fat globules,
which reduces ice crystal formation and growth. This leads to a smoother texture
and slower melting rate, crucial for consumer acceptability, especially in warmer
climates. However, while increasing fat content improves texture and stability, it
also raises concerns regarding the nutritional profile, specifically caloric content
and potential health impacts. Therefore, balancing fat content to achieve desirable
sensory qualities without compromising health standards is essential.

Stabilizers

Stabilizers play a pivotal role in maintaining the structural integrity and

consistency of ice cream. They prevent the formation of large ice crystals during
freezing and storage, thereby enhancing the smoothness and creaminess of the
product.

Interaction Between Fat and Stabilizers

The study underscored the necessity of optimizing the interaction between fat
content and stabilizers to achieve the best possible ice cream quality. For
instance, a combination of moderate fat content with an appropriate amount of
stabilizer provided a balanced profile with desirable textural and sensory
attributes without excessive caloric content. Conversely, low-fat formulations
required a higher concentration of stabilizers to compensate for the lack of fat,
which could sometimes lead to undesirable textural properties if not carefully
controlled.

Sensory Evaluation and Consumer Acceptance

Sensory evaluations highlighted the preferences of consumers for creamier

textures and richer flavors associated with higher fat content. However,
healthconscious consumers showed a preference for low-fat formulations that still
offered acceptable sensory qualities. This indicates a market for both high-fat,

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premium ice creams, and lower-fat, health-oriented options, each requiring
specific formulation strategies.

Industrial Implications

For the ice cream industry, these findings offer valuable guidance in formulating
products that meet diverse consumer preferences. The ability to manipulate fat
content and stabilizer type and concentration allows for the creation of a wide
range of ice cream products, from indulgent, rich varieties to lighter,
healthfocused alternatives. Moreover, understanding these interactions can aid in
developing new products with extended shelf life, improved stability, and
enhanced sensory attributes.

In conclusion, the study successfully delineates the significant effects of fat and
stabilizers on the physicochemical and functional properties of ice cream. These
insights provide a robust foundation for optimizing ice cream formulations,
balancing quality with health considerations, and meeting the evolving demands
of consumers in a competitive market.

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7) Future Scopes

1. Molecular Interactions: Conduct molecular-level studies to understand the

interactions between fat globules, stabilizers, and other ice cream
components, which can lead to the development of optimized formulations
with enhanced functional properties.
2. Sensory Optimization: Utilize consumer preference mapping and sensory
analysis to tailor ice cream formulations to specific market segments, focusing
on regional taste preferences and dietary requirements.
3. Thermal Stability: Explore the development of ice cream formulations with
improved thermal stability to withstand temperature fluctuations during
storage and distribution, reducing the risk of ice crystal formation and texture
degradation.
4. Nutritional Enhancements: Investigate the incorporation of functional
ingredients, such as probiotics, prebiotics, and dietary fibers, in conjunction
with fat and stabilizers to create ice cream with added health benefits.
5. Shelf Life Extension: Study the impact of fat and stabilizers on the shelf life
of ice cream, focusing on strategies to extend product freshness and quality
over prolonged storage periods.
6. Environmental Impact: Assess the environmental sustainability of various
fat sources and stabilizers, promoting the use of eco-friendly ingredients and
production practices in the ice cream industry.
7. Personalized Nutrition: Develop customizable ice cream formulations tailored
to individual dietary needs and preferences, leveraging advances in food
technology and nutrition science.
8. Regulatory Compliance: Examine the regulatory aspects of using novel fat
sources and stabilizers, ensuring that new formulations comply with food
safety standards and labeling requirements.
9. Functional Ice Creams: Create ice cream formulations designed for specific
functional benefits, such as enhanced energy, improved digestion, or fortified
with essential vitamins and minerals.

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10. Interactive and Smart Packaging: Research packaging solutions that can
interact with ice cream formulations to further stabilize the product,
provide realtime freshness indicators, and reduce spoilage.

These future research directions aim to enhance the quality, functionality,

and consumer appeal of ice cream, while addressing health, sustainability,
and regulatory considerations.