UNIT 9 PRINCIPLE AND METHOD OF

MANUFACTURE
Structure
9.0 Objectives
9.1 Introduction
9.2 Principle and method of manufacture
9.3 Ingredients
9.4 Preparation of Ice Cream Mix
9.5 Pasteurization of Ice cream mix
9.6 Homogenization of mix
9.7 Cooling and Ageing of mix
9.8 Freezing of Mix
9.9 Overrun in ice cream
9.10 Let us sum up
9.11 Key words
9.12 Some useful books
9.13 Answers to Questions

9.0 OBJECTIVE
After reading this unit we shall be able to:
• know method of manufacture of ice cream on large scale.
• select the ingredients required for preparing ice cream mix.
• calculate the mix- ingredients required
• know processing steps like pasteurization, homogenization, ageing and freezing
of ice cream mix.
• name equipments used for freezing ice cream.
• understand overrun in ice cream.

9.1 INTRODUCTION
Ice cream is one of the most popular frozen dairy products. The methods of
production vary according to the type and volume of production. The methods of
manufacture may be grouped as (a) Home production (b) Small- scale production
and (c) Large scale manufacture. When ice cream is prepared at home, the mix
generally consists of milk, cream sugar, egg and corn flour. It is usually made in
small quantities for early domestic consumption only. Many types of home freezers
are now available in the market for ice cream preparation. Since only small quantities
are prepared for early consumption, the control of home- made ice cream is relatively
20
unimportant. Small producers of ice cream use whole, skimmed or condensed milk,
milk powder, sugar, egg and stabilizers for the manufacture of ice cream. Majority Principle and Method of
Manufacture
of the small-scale producers of ice cream are ignorant of basic and simple methods
of hygienic production of ice cream. Consequently, the ice cream manufactured by
them is invariably contaminated with disease producing microorganisms. Consumption
of such contaminated product may lead to many types of diseases. Children,
especially, are more vulnerable. If proper care and control are maintained at
production level, good quality ice cream can be manufactured. When large quantities
of ice cream are to be made, manufacturing methods are more controlled and
hygienic. Ice cream is now being scientifically prepared under strict hygienic condition
in organized dairy sector. Ice cream being a formulated food, it is necessary to
select the required ingredients in proper amount so that the desired flavour, body
and texture characteristics are obtained in the ice cream. Whatever ingredients are
used in the manufacture of ice cream, they should be of very high quality.

9.2 PRINCIPLE AND METHOD OF

MANUFACTURE
The first step in the manufacture of ice cream is to prepare ice cream mix. This
involves assembling of various ingredients. In order to produce good ice cream
both dairy ingredients and non-dairy ingredients must be selected and combined so
as to produce the desired body, texture and the delicate flavour in the ice cream.
Obviously selection of good and wholesome ingredients will only help to produce
good quality product. Knowledge of the properties of the ingredients and their specific
role in maintaining the body, texture and flavour characteristics in ice cream will be
very useful in the selection of suitable ingredients for the ice cream mix preparation.
Preparation of the mix involves assembling various ingredients, weighing and mixing
them in a vat or tank and subjecting the mixture to further processing like
pasteurization, homogenization, cooling and ageing. Aged ice cream mix is then partially
frozen in a suitable ice cream freezer. The partially frozen ice cream from ice cream
freezer is then filled in suitable containers (packaging materials) and further frozen in
a hardening chamber at a very low temperature. The hardened ice cream is then
stored at the same temperature until released for consumption. In this unit, the
selection of ingredients for the preparation of ice cream mix, processing of mix and
freezing of ice cream mix will be discussed briefly.
Selection of Ingredients

Calculation of mix ingredients

Preparation of ice cream mix

Pasteurization of mix

Homogenization of mix

Ageing of mix

Freezing of mix

21
Packaging of ice cream
Frozen Dairy Products

Hardening of ice cream

Storage of ice cream

Fig. 9.1. Flow diagram of Manufacture of Ice Cream

9.3 INGREDIENTS
The selection of good ingredients is without doubt the most important factor in the
manufacture of good quality ice cream. A clean, fresh, creamery flavour in ice
cream can be secured only by the use of products, which have been carefully selected
and used. Ingredients are the substances, which contribute the fat, non-fat solids,
sweetening, flavouring, colouring, stabilizing and emulsifying materials to ice cream
mix. Selection of suitable ingredients for the ice cream mix preparation depends on
the following points.
i) Products availability
ii) Perishability of products
iii) Convenience in handling
iv) Effect on flavour and body and texture of ice cream
v) Cost
vi) Equipment available for processing
The ice cream mix ingredients may be grouped as (a) Dairy products and (b) Non-
dairy Products. Dairy products are the source for milk fat and non-fat milk solids in
the ice cream. Non-dairy products are the source for sweeteners, stabilizers,
emulsifiers, colours and flavours.
i) Milk fat products: The following products, which have higher milk fat contents
are the source for supply of milk fat in the ice cream preparation.
a) Sweet cream
b) Frozen cream
c) Plastic cream
d) Unsalted butter
e) Butter oil.
Besides above materials, the following materials may also serve as source for
fat. In addition, these materials also provide non-fat milk solids:
a) Whole milk
b) Whole milk powder
c) Condensed whole milk (plain/sweetened)
d) Evaporated milk
ii) Milk protein/non-fat products: These include the following:
22 a) Skim milk
 b) Skim milk powder Principle and Method of
Manufacture
c) Condensed skim milk (plain/sweetened)
d) Sweet cream butter milk
iii) Sugars and other sweetening agents: Many kinds of sweetening agents are
used in the preparation of ice cream. Cane sugar (sucrose) is the most commonly
used sweeteners in ice cream. Other sweeteners used are beet-sugar, glucose
syrup, dextrose, fructose, honey, invert sugar, corn syrup and artificial sweeteners
like saccharin etc. About 13-15 per cent cane sugar is generally considered
adequate for ice cream. Part of the cane sugar can also replaced by other
sweetening agents like glucose syrup, corn solids, honey etc. The amount
sweeteners is accordingly adjusted to get the desired sweetness in ice cream.
iv) Stabilizers and Emulsifiers: The purpose of adding stabilizing in ice cream
is to obtain smooth body and texture. They help in improving the water holding
ability of ice cream mix and thereby help to obtain smooth body and texture.
They also help to prevent large ice crystal formation during storage of ice cream.
Excess amount of stabilizer would cause soggy or gummy body in ice cream
and reduce whipping ability. Whipping ability of ice cream mix refers to the
ease with which air can be incorporated into ice cream mix. The size of the air
cells and the maximum overrun, which can be attained.
Emulsifier helps to emulsify fat in ice cream mix. It improves the whipping
ability and provides a dry ice cream with smooth body and texture. Too
much of emulsifier may cause excessive foaming in ice cream and cause shrinkage
during storage.
The following substances are used as stabilizers in ice cream:
Gelatin, Sodium alginate, Guar gum, Carboxy methyl- cellulose, Agar-agar,
Carrageenan, Locust bean gum
The following two kinds of emulsifiers are used in ice cream:
a) Mono and di-glycerides derived from chemical reaction of naturally
occurring triglycerides, e.g., glycerol monostearate (GMS)
b) Polyoxyethylene derivatives of hexahydric alcohols, glycol and glycol
esters-e.g. Tween- 80
v) Flavouring and colouring agents: Flavour is an important aspect of ice cream.
Ice cream is valued mainly for the pleasing flavour. Many flavours, both natural
and artificial are available for providing flavour substance for ice cream. In the
selection of flavouring material, it is important to consider the quality of ice
cream mix in which they are to be used. Slight off-flavours in the mix may
obscure the delicate flavour of the flavouring material. Flavouring substances
of natural and artificially produced are available mainly in mixtures for flavouring
food products. Vanilla flavour is the most widely used flavour in ice cream
followed of cocoa/chocolate flavour.
Natural flavours available for addition to ice cream are from (a) All fruits (b)
Vanilla beans (c) Cocoa and chocolate (d) Coffee extract etc.
Synthetic flavours include a) Aromatic chemicals, and b) Imitation of flavours.
vi) Colours: Ice cream should have a delicate attractive colour which suggests or
is associated with the flavour. Only harmless, edible and permitted food colours 23
Frozen Dairy Products should be used. Care should be taken to use only those colours, which are
permitted under PFA rules.
vii) Miscellaneous ingredients: Special ice creams like fruit ice cream or nut ice
cream use fresh fruits or nutmeats in their preparation. Fresh fruits or frozen
fruits are used in the preparation of fruit ice cream. Fruits like strawberry,
raspberry, peaches, pineapple, mango etc. are generally used in the preparation
of fruit ice cream. The amount of fruit required to impart flavour varies with the
desired characteristic intensity of flavour. This amount varies from 10 to 25
per cent of weight of the finished product.
Among nuts, almonds, pistachios, walnuts, peanuts are some of the nuts popular
in nut ice creams. The nutmeats used in the ice cream should be clean and free
from any bacterial contamination. About 3-6 percent of nut preparation may
be used in the nut ice cream. Cocoa or chocolate or egg or egg products are
also used as optional ingredients in ice-cream.
Check Your Progress I
1. Name three categories under which ice cream is generally produced.
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2. In home production, how ice cream is basically prepared.
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3. Why children may fall sick on consumption of ice cream produced by some
small-scale producers.
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4. What is the first step in the preparation of ice cream?
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5. Which dairy ingredients are good source of milk-fat?
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6. Which dairy ingredients are good source of non-fat milk solids?
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24
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7. Which dairy ingredients can provide both milk fat and non-fat milk solids? Principle and Method of
Manufacture
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8. Which sweetening substance is used widely in the ice cream preparation?
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9. What other sweetening agents can be used in ice cream?
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10. What is the purpose of adding stabilizer in ice cream?
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11. What is the purpose of emulsifier in ice cream?
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9.4 PREPARATION OF ICE CREAM MIX

Ice cream is composed of a mixture of both dairy and non-dairy food ingredients
such as milk products, sweetening agents, stabilizers, emulsifiers, flavours and
colouring materials. As already seen earlier, wide variety of ingredients could be
used to produce ice cream mix. The effect of these ingredients upon the finished
product is due to the constituents of the ingredients.
An ice cream mix is the unfrozen blend of the different ice cream ingredients. It
consists of all the ingredients of ice cream with the exception of flavour material and
air. Flavour is added only at the time of freezing and air is incorporated into the mix
during freezing. The composition of ice cream is usually expressed as percentage of
its constituents. A satisfactory composition produces an ice cream having desired
flavour body and texture characteristics. An ice cream mix with such a satisfactory
composition is called a “Balanced mix”. Thus a balanced ice cream mix is one in
which the proportions of the constituents and ingredients are such that they combine
to produce an ice cream of satisfactory quality.
i) Calculation of Mix-Ingredients: To prepare ice cream mix various ingredients
are mixed. It is necessary to know how much of each ingredient should be
added to produce a balanced mix. Addition of exactly calculated amount of
ingredients will help to produce ice cream of uniform quality. This will also 25
Frozen Dairy Products ensure ice cream produced meets the legal standards prescribed for ice cream.
Knowledge of calculation, therefore, is helpful in properly balancing the ice
cream mix.
Algebraic method is one method for calculating the amount of ingredients
required for ice cream preparation.
The final composition desired in ice cream is decided first. Suppose ice cream
with the following composition is to be prepared:
Fat – 12.0%
SNF – 11.0%
Sugar – 15.0%
Stabilizer & Emulsifier v 0.5%
Total = 38.5%
The ingredients available are:
Milk – 3.5% fat; 8.5% SNF
Cream – 40.0% fat; 5.28 SNF
Skim milk powder – 1.0% fat; 96.0% SNF
Sugar, Stabilizer + Emulsifier – It is assumed that sugar, stabilizer
and emulsifier contribute 100% solids.
It is convenient to calculate the required amount of ingredients for preparing
100 kg of ice cream mix.
ii) Calculation for 100 kg Ice cream mix: Since sugar and stabilizer + emulsifier
in the mix are 15.0% and 0.5% respectively, the ice cream mix will have 15.0
Kg sugar and 0.5 Kg stabilizer + emulsifier. It means that out of 100.0 Kg of
mix, 15.5 Kg comes from the mixture. The balance of (100 –15.5) kg== 84.5
Kg comes from the mixture of milk, cream and skim -milk powder.
Assume A Kg milk, B Kg cream and C Kg skim-milk powder are used.
The values for A, B and C could be calculated by forming algebraic equation
and solving the equation.
In 100 Kg ice cream mix the following will be there:
Milk – A Kg
Cream – B Kg
Skim milk powder – C Kg
Sugar – 15.0 Kg
Stabilizer + emulsifier – 0.5 Kg
Total = 100 Kg
A + B + C + 15.0 + 0.5 = 100.0
or A + B C = 100.0 – (15.0 + 0.5)
26 or A + B C = 84.5 — Equation (1)
In 100 Kg of mix 12 Kg milk fat (12%) is present. This amount comes from A Kg Principle and Method of
Manufacture
milk, B Kg cream and C Kg skim milk powder. Since the fat percent in each
ingredient is known an equation for fat can be made.
3.5 40.0 1.0
∴ ×A + × B+ × C = 12
100 100 100
or 3.5 × A + 40.0 × B + 1.0 × C = 1200 Equation (2)
Similarly equation for SNF content is formed:
8.5 5.28 96.0
×A + ×B + × C = 11
100 100 100
8.5 5.28 96.0
or 8.5 × A + 5.28 × B + 96.0 × C = 1100 Equation (3)
To eliminate one known value (Say A) multiply the equation (1) by 3.5
i.e. 3.5 (A + B + C) = 84.5 × 3.5
or 3.5 × A + 3.5 × B + 3.5 × C = 84.5 × 3.5 = 295.75
Subtract this equation from equation (2)
3.5 × A + 40.0 × B + 1.0 × C = 1200.00
3.5 × A + 3.5 × B + 3.5 × C = 295.75
36.5 × B – 2.5 × C = 904.25 Equation (4)
Similarly to eliminate A from equation (3) multiply equation (1) by 8.5 and subtract
from equation (3).
8.5 (A+B+C) = 84.5 x 8.5
or 8.5 x A + 8.5x B + 8.5 x C = 84.5 x 8.5 = 718.25
8.5 A + 5.28 x B + 96.0 x C = 1100
8.5 A + 8.50 x B + 8.5 x C = 718.25
3.22 × B + 87.5 × C = 318.75 Equation (5)
To eliminate B, multiply equation (4) by 3.22 and equation (5) by 36.5
∴ 3.22(35.5 × B – 2.5 × C) = 3.22 × 904.25(Equation 4)
36.5(-3.22 × B - 87.5 × C) = 35.5 × 318.75(Equation 5)
or 3.22 × 35.5 × B – 8.05 × C = 2911.685 —- Equation (6)
36.5 × 3.22 × B + 3193.75 C = 13933.875 —- (Equation (7)
3185.70 C = 16845.56
∴ 3185.70 C = 16845.56
∴ C = 16845.56
————— = 5.28
3185.70
∴Quantity of skim milk powder required = 5.28 27
Frozen Dairy Products Substitute the value of C (= 5.28) in equation (4)
∴ 36.5 x B – 2.5 x 5.28 = 904.25
or 36.5 x B – 13.20 = 904.25
or 36.5 x B = 904.25 + 13.20
36.5 x B = 917.45
or B = 917.45
———— = 25.13
36.5
∴ Quantity of Cream required = 25.13 Kg
Substitute the value of C (=5.28) & B (=25.13) in equation (1)
∴ A + 25.13 + 5.28 = 84.5
or A = 84.5 – (25.13 + 5.28)
= 54.09
∴ Quantity of Milk required = 54.09 Kg.
∴
Proof Sheet: 100 Kg of ice cream mix will have the following ingredients:
Ingredients Quantity (Kg) Fat SNF T.S
Milk 54.09 1.90 4.60 6.50
Cream 25.13 10.05 1.33 11.38
Skimmilk powder 5.28 0.05 5.07 5.12
Stabilizer + 0.50 - - 0.50
Emulsifier
Sugar 15.00 - - 15.00
Total 100.0 12.00 11.00 38.50

9.5 PASTEURIZATION OF ICE CREAM MIX

All liquid ingredients (milk; cream etc.) are placed in stainless steel tank provided
with a stirrer. The heating of liquid ingredients is started with stirring. The mix
ingredients are mixed thoroughly. The dry ingredients (skim-milk powder, sugar,
stabilizer etc.) are then added slowly with proper mixing. The heating of the mixture
continued up to 49-50°C while mixing the ingredients. If gelatin is used as stabilizer,
it is added to the liquid ingredients before heating started. If sodium alginate is used
as stabilizer, it should be added when the temperature of mix reaches 65°C or
above. It should never be added to cold mix. Proper pasteurization of all mixes is
compulsory because this process gives the following advantages:
a) Destroys all pathogenic or disease producing bacteria, thereby safe guarding
the health of the consumer:
b) Brings the ingredients of the mix in to solution and aids in blending.
c) Improves flavour.
28 d) Improves keeping quality.
e) Produces a more uniform product. Principle and Method of
Manufacture
Proper pasteurization consists of rapidly heating the mix to a definite temperature,
holding it at that temperature for a definite period of time and then rapidly cooling to
below 5°C.
The recommended pasteurization temperature-time combination for ice cream mix
are as follows:
a) Batch method = 68.5°C for not less than 30 minutes
b) High temperature -Short time (HTST) Method = 80.0°C for not less than 20
seconds
The present trend is towards higher temperature processes like Ultra high temperature
for few seconds.

9.6 HOMOGENIZATION OF MIX

Homogenization of ice cream mix is essential. The main purpose is to make a
permanent and uniform suspension of the fat by reducing the size of the fat droplets
preferably of the size of not more than 2 microns in diameter. When mix is properly
homogenized the fat will not rise and form a cream layer. The ice cream mix is
usually homogenized at temperatures above 60°C. Use of higher temperatures in
homogenization process has the following advantages:
a) Results in less clumping of fat globules
b) Lower viscosity in mix
c) Reduces freezing time in batch ice cream freezers.
Two-stage homogenization of ice cream mix is more suitable than one stage
homogenization. In two stage homogenization a pressure of about 175 Kg/Sq. cm
to 205 Kg/Sq. cm in the first stage and 35 Kg/Sq. cm in the second stage gives
good results for average mix. It is preferable to homogenize ice cream mix at
pasteurization temperature. The advantages of homogenization of mix are:
a) Fat globule size is reduced and hence no cream layer formation.
b) Produces more uniform ice cream with a smooth texture.
c) Improves whipping ability.
d) Reduces ageing period.
e) Reduces the amount of stabilizer required in ice cream mix.

9.7 COOLING AND AGEING OF MIX

Cooling of the mix immediately after pasteurization and homogenization is essential.
The mix should be cooled to 4.0°C or below. Cooling is usually done using surface
coolers, tubular coolers or other type of heat exchangers. The temperatures below
4°C retard the growth of bacteria. Ageing refers to holding the ice cream mix at a
low temperature for a certain period of time before freezing. The ageing temperature
should not exceed 4.5°C. The ageing time under average commercial conditions
may be about 4 hour only. It may be increased depending upon the type of stabilizer
in the mix:
29
Frozen Dairy Products Following changes occur in the ice cream mix during ageing:
i) Fat is solidifies
ii) Stabilizer swells and combines with water.
iii) Viscosity increases.
Ageing of ice cream mix offers the following advantages:
i) Improves body and texture of ice cream.
ii) Improves whipping ability of mix.
iii) Increases maximum overrun.
iv) Increases melting resistance of mix.
Check Your Progress II
1. What is a balanced ice cream mix?
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2. What are the advantages of pasteurization?
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3. What is the recommended temperature time combination for Batch and HTST
pasteurization?
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4. What are the advantages of homogenization of mix?
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5. What do you mean by ageing of ice cream mix?
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6. What changes occur in ice cream mix during ageing?
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7. What are the advantages of ageing? Principle and Method of
Manufacture
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9.8 FREEZING OF MIX

When the mix has been properly aged it is ready for next step, that is, freezing.
Freezing is one of the most important operations in the preparation of ice cream,
because, upon this depends the quality, palatability and yield of the finished product
The freezing process may be divided as follows into two parts:
a) The mix with colour and flavouring materials added is quickly frozen in the ice
cream freezer. During freezing, the mix is agitated to incorporate air in such a
way as to produce and control the formation of small ice crystals so necessary
to give smoothness in body and texture, palatability and satisfactory overrun in
the ice cream.
b) The mix partially frozen to a certain consistency in the ice cream freezer is
drawn out from freezer into packages and quickly transferred to cold storage
rooms where the freezing and hardening process is completed without agitation.
Fast freezing is essential for smooth textured ice cream because ice crystals
that are formed quickly are smaller than those formed slowly. Therefore it is,
desirable to freeze and draw out from the freezer in a short time as possible. A
continuous freezer accomplishes this in few seconds, while batch freezer takes
6 to 10 minutes or more time depending upon several factors. Also, since
freezing continues after ice cream is placed in the hardening rooms, the ice
crystals formed during the hardening period are larger because they form more
slowly than in the freezer. For this reason, it is desirable to freeze the ice cream
as stiff as possible and yet have it liquid enough to draw out of the freezer.
i. Types of Ice Cream Freezers
The equipment used for partial freezing of ice cream mix is called ice cream freezer.
Three types of ice cream freezer are identified
i) Batch freezer : It consists of a refrigerated drum or cylinder provided with a
dasher and scrapper fitted in to it. An electric motor drive turns the dasher
assembly within the cylinder. The scrapper removes the frozen ice cream from
the refrigerated surface and dasher whips the ice cream to introduce air into it.
Freezer is also filled with a hopper to introduce fruits and flavour. Commercial
freezers vary from 5 litres to 50 litres capacity.

Fig. 9.1 cSp fgedkjh

31
Frozen Dairy Products The batch freezer consists of freezing chamber and a dasher. The dasher assembly
comprises of two parts, viz., the scrapper blades and the beater.

Fig. 9.2 eFkkuh lTthdj.k

The dasher performs the following functions:

• Aids in transmission of refrigeration by keeping mix in continuous contact with
freezer walls.
• Scraps freezer walls free from ice crystal.
• Incorporates air.
• Pushes mix continuously forward (this helps to unload ice cream from freezer).
• The temperature of the refrigerant circulating in the freezer should be below
– 23°C to get rapid formation of ice crystals.
Freezing procedure in the batch freezer: The mix is run into the freezer, the
dasher started and then the refrigerant is turned on. This sequence must be observed
at all times to avoid damage to the machine. The flavouring and colouring materials
are added to the mix. The total volume of the mix, flavour and colour should be
about half the total volume of the freezing chamber. To avoid variation from batch to
batch, each batch of mix must be measured carefully before putting in to the freezer.
The freezing operation must be closely watched to know the correct time to shut-off
refrigeration. This comes mostly by experience of the operator. If the refrigerant is
allowed to run for a longer period the following problems may arise.
• Difficulty in obtaining the desired overrun
• Mix becomes stiff
• Whipping becomes difficult
After refrigerant is shut-off, the freezer without certain limits continue to operate,
incorporate more air, freezing more of water until the product attains both the desired
overrun and desired consistency. The ice cream from the freezer should be emptied
into the container/package as rapidly as possible to avoid fluctuations in overrun in
packages. When the ice cream is drawn from the freezer it should be stiff enough to
hold its shape and yet soft enough to loose its shape within a short time.
Cleaning of batch freezer: After the last batch of ice cream is drawn, the freezer
is first flushed with water. The rinse water should not be very hot. During rinsing
operation the dasher should be turned only a few revolutions. The dasher and other
removable parts should be removed to a sink and thoroughly scrubbed with a hot
(about 50°C) detergent solution, rinsed, sanitized and stored where they may dry.
The freezer chamber is also scrubbed with hot detergent solution, rinsed and left
32 open to dry.
ii) Continuous Freezer: The process consists of continually feeding into end of Principle and Method of
Manufacture
the freezing chamber a metered amount of ice cream mix and air. As the mixture
passes through the freezing chamber it is agitated, partially frozen and then
discharged in a continuous stream of about same consistency usually obtained
from a batch freezer.

Fig. 9.3 lrr fgedkjh

The continuous freezers are of two types: One type has two pumps at the back
of the freezer barrel. One pump pulls mix from the supply tank and pumps into
second pump. The second pump operates at a speed almost twice that of the
first pump. This has the effect of creating a partial vacuum between the two
pumps. A valve device in the piping between the pumps allows air to be sucked
in. The amount of air incorporated, in the mix can be regulated by a control
valve. The mix and the air both are pumped into the freezer’s barrel by the
second pump. As mix freezes, semi-frozen ice cream is forced out of the front
end.
The second type of continuous freezer operates in a similar fashion. However
the two pumps are at the front end. One pump pushes the mix into the back
end of the freezer and the other helps to pull the semi frozen ice cream from the
freezer barrel. There is a separate pump that forces air directly into the freezer
barrel.
In the continuous freezer, the mix is continuously pumped into the machine and
the frozen product is continuously discharged from the machine. Initially, the
amount of air introduced is regulated to give the desired overrun in the ice
cream. The temperature of refrigerant on the freezing chamber is adjusted to
give the desired consistency when the product leaves the machine.
Cleaning of continuous freezer: Method of cleaning continuous freezer is
similar to the methods of cleaning most of the dairy equipments. Remove all
pipelines, which carry ice cream mix to the freezer. Remove the front of freezer
unit and pull out the freezer dasher. Rinse all parts of machine, which come in
contact with ice cream mix, with warm water (35°C-40°C). Flush the freezing
tube with cold water followed by warm water. Thoroughly wash and clean all
parts of freezer with hot detergent solution. Rinse with hot water to remove all
traces of detergent. Finally rinse with scalding hot water and allow it to dry.
iii) Soft serve freezer: This is similar to batch the freezer in construction and
operation with lesser capacity. The overrun obtained in this type of freezer is
less than that is obtained in batch freezer. Time taken for freezing ice cream in
the freezer will dependent on many factors. Some factors are mechanical while
some others due to the property of ice cream mix. 33
Frozen Dairy Products

Fig.9.4e`nqlsokfgedkjh

ii. Factors Influencing Freezing

These factors may be mechanical factors and the factors related with the properties
of the mix as listed below.
A) Mechanical factors:
• Type and make of ice cream freezer.
• Condition of freezer wall and blades.
• Speed of dasher.
• Temperature of refrigerant.
• Velocity of refrigerant passing around freezing chamber.
• Overrun desired.
• Temperature at which ice cream is drawn.
• Rate of unloading of freezer.
B) Characteristics of mix or property of mix:
• Composition of mix.
• Freezing point of mix.
• Acidity content of mix.
• Kind of ingredients, particularly those carrying fat.
• Methods of processing mix.
• Kind and amount of flavouring materials used.
Freezing time and temperature: The freezing time and temperature of different
types of ice cream freezers are given below in Table 9.1.
Table 9.1 Freezing time temperature for different freezers
Kind of freezer Freezing time to Drawing temperature
90% overrun
°C °F
(approximate)
Batch freezer 7 minutes -3 to -4 24-26
Continuous 24 seconds -5 to -6 21-22
freezer
Soft-serve 3 minutes -7 to -8 18-20
freezer

34
Changes occurring during freezing: The functions of the freezing process are Principle and Method of
Manufacture
listed below.
• To freeze a portion of water of the mix
• To incorporate air into the mix.
This involves:
• Lowering of the temperature of the mix from ageing temperature to the freezing
point.
• Freezing a portion of water of the mix.
• In-corporation of air into the mix.
• Cooling the ice cream from the temperature it is drawn from the freezer to
hardening room temperature.
The temperature of the mix in the freezer drops rapidly while the sensible heat is
being removed and before the ice crystals are formed. This process takes less than
a minute or two. Rapid agitation of the mix reduces the viscosity of the mix. Also
rapid agitation hastens incorporation of air into the mix. When freezing point is
reached, water in the mix starts freezing and ice crystals are formed. As part of
water is converted into ice crystals, the concentration of sugar in the remaining water
increases causing the freezing point of the mix to be lowered. So the temperature of
the mix must be lowered before some more ice crystals could be formed. Thus, the
freezing point is continuously being lowered by the formation of more ice crystals
while temperature drops. The first phase of the freezing process accounts for freezing
33 to 67% of water depending on the drawing temperature. The hardening process
then may account for the freezing of remaining portion of water up to 90-95%.
During this period when the temperature of ice cream mix is being lowered and ice
crystals are being formed, ingredients such as acid fruit juices fruits and nuts may be
added without any danger of coagulation of the mix. During this process more air is
also incorporated into the mix due to agitation. Freezing process gives a definite
texture to the ice cream. The texture of ice cream depends on the size and no of air
cells and ice crystals and unfrozen materials in the ice cream. Air cells are dispersed
in a continuous liquid phase with embedded ice crystals. The liquid phase contains
solidified fat particles, milk proteins, in-soluble salts, stabilizers and some lactose
crystal. Sugar, part of lactose and soluble salts are in true solution.

9.9 OVERRUN IN ICE CREAM

Overrun is usually defined as the volume of ice cream obtained in excess of the
volume of the mix. It is usually expressed as “percent overrun”. The increased
volume is composed mainly of air incorporated during the freezing process. The
amount of air which should be incorporated depends upon the composition of the
mix and the way it is processed and is regulated so as to give that percent overrun
which will give proper body, texture and palatability to the ice cream. Too much air
will produce a snowy fluffy ice cream while too less air on the other hand will lead to
soggy, heavy ice cream.
i) How to obtain and control overrun: The following factors need to be
considered in determining the amount of overrun in ice cream.
• Legal regulation enforced in the market area.
• Total solids content of the ice cream mix. 35
Frozen Dairy Products • Type of ice cream to be made (fruit/nut ice cream etc.)
• Selling price of ice cream.
• Type of packages.
The overrun attainable at the freezer depends upon the following points:
• Type of ingredients used in the mix.
• Sharpness of scrapper blades.
• Speed of dasher.
• Volume of refrigerant passing over freezing chamber.
• Temperature of refrigerant
The use of proper overrun tester will ensure uniform overrun. The control of overrun
is very important and should be maintained as nearly constant as possible from
batch to batch.
ii) The per cent overrun: The percent overrun in different types of ice creams is
given in Table 9.2
Table 9.2 Per cent over run
Type of ice cream Percent overrun
Ice cream, packaged 70-90
Ice cream bulk 90-100
Soft-serve ice cream 30-50

iii) Failure to obtain the desired overrun: Due to the following factors one fails
to obtain overrun in ice cream
• Longer time to obtain overrun.
• Too high drawing temperature.
• Very soft ice cream.
• Tendency to form ice cream with coarse texture because of large is crystal
formed.
iv) Method of calculating percent overrun: There are following two methods
by which the percent overrun can be calculated.
1) By volume
Volume of ice creasm – Volumeof mix
% Overrun = × 100
Volume of mix
10 litres of ice cream mix are frozen to make 19 litres of ice cream” What is the
overrun in the ice cream.”
Volume of ice cream mix = 10 litres
Volume of ice cream = 19 litres
Volume of ice cream – Volume of mix 19 –10
36 ∴ % Overrun = = × 100 = 90%
Volume of mix 10
2) By weight Principle and Method of
Manufacture

Weight of unit Weight of same unit

Volume of mix – Valume of ice cream
× 100
Weight of unit valume of ice cream
Weight of 100 ml of ice cream mix = 110 gm
Weight of 100ml of frozen ice cream = 55 gm
What is the % overrun in ice cream?
Wt. of unit vol. of mix –Wt. of same unit vol. of ice cream
Wt.of unit vol.of mix – Wt.of same unit vol.of ice cream
% Overrun = × 100
Weight of same unit volume of ice cream
110 – 55 55
× 100 = × 100 = 100%
55 55
Check Your Progress III
1. What happens during freezing of ice cream mix?
...................................................................................................................
...................................................................................................................
...................................................................................................................
2. What is the important of fast freezing?
...................................................................................................................
...................................................................................................................
...................................................................................................................
3. Name three types of ice cream freezers used.
...................................................................................................................
...................................................................................................................
...................................................................................................................
4. Time taken for freezing of mix depend on what two main factors?
...................................................................................................................
...................................................................................................................
...................................................................................................................
5. What changes take place during freezing?
...................................................................................................................
...................................................................................................................
...................................................................................................................
37
Frozen Dairy Products 6. Define overrun in ice cream.
...................................................................................................................
...................................................................................................................
...................................................................................................................
7. What factors should be considered for determining the amount of overrun in
ice cream?
...................................................................................................................
...................................................................................................................
...................................................................................................................
8. The overrun attainable in ice cream depends on what points?
...................................................................................................................
...................................................................................................................
...................................................................................................................

9.10 LET US SUM UP

Ice cream is one of the most popular frozen desserts. It is a formulated food. The
ingredients used in the manufacture of ice cream largely influence the overall quality
(flavour, body &texture, colour, melting characteristics etc.) of the finished product.
It is, therefore, important to know the properties of each ingredient and its specific
role in ice cream. It is also necessary to select the appropriate and good quality
ingredient in required quantity in order to manufacture good quality ice cream with
desired characteristics. The basic steps in the preparation of ice cream involve proper
blending of both dairy and non-dairy ingredients. Dairy ingredients include sources
for milk fat such as milk, cream, butter, SMP/WMP, condensed milk, evaporated
milk, skim milk etc. Non-dairy ingredients include sources for non-fat constituents
such as sweeteners eg. cane sugar, beet-sugar, glucose syrup, dextrose, fructose,
honey, invert sugar, corn syrup and artificial sweeteners like saccharin; stabilizers
eg., gelatin, sodium alginate, guar gum, carboxy methyl cellulose, agar-agar,
carrageenan, and locust bean gum; emulsifiers eg., mono and diglycerides, hexahydric
alcohols, glycol and glycol esters; appropriate colour and flavour etc. In a nutshell,
preparation of ice cream involves, selection of all required ingredients, calculation of
mix ingredients as per the desired composition, preparation of balanced ice cream
mix, pasteurization of mix, homogenization of mix in two stages, ageing of mix at 4 -
5°C/ 4-12 h, freezing of mix by using batch or continuous or soft serve freezers,
packaging of ice cream in cups or paper board boxes or any other appropriate
packaging material and hardening of ice cream in a hardening chamber maintained
at -23 to -25°C until sold to consumer.
Overrun is defined as the volume of ice cream obtained in excess of the volume of
the mix and is expressed as ‘per cent overrun’. It is due to incorporation of air
during the freezing process. Too much air incorporation will produce a snowy and
fluffy ice cream and too less air in the ice cream will lead to soggy and heavy ice
cream.

38
 Principle and Method of
9.11 KEYWORDS Manufacture

Balanced mix : is the base mix of ice cream with both dairy
ingredients and non-dairy ingredients in
proper proportion and exact quantity required
in order to produce ice cream of uniform
quality.
Whipping ability : is the ability of the ice cream to incorporate
air during freezing in the form of very small
everrun which can be attained process and
retain it.
Stabilizers : are the non-dairy ingredients used in the
preparation of ice cream in order to improve
its whipping ability and prevent the formation
of large sized ice crystals.
Emulsifiers : are the non-dairy ingredients used in the
preparation of ice cream to emulsify fat in ice
cream mix. It improves the whipping ability
and provides dry ice cream with smooth body
and texture.
Ageing : is the process holding the ice cream mix at a
low temperature for a certain period before
freezing.
Freezing : is the process of incorporation of air along
with continuous agitation and cooling of ice
cream mix in such a way as to partially frozen
the mix to a certain consistency while drawing
from freezer.
Overrun : is the volume of ice cream obtained in excess
of the volume of the mix taken. and expressed
as ‘per cent overrun’.

9.12 SOME USEFUL BOOKS

Outlines of Dairy Technology Sukumar De Oxford University Press, Delhi
3Ice cream W.S. Arbuckle (1986) The AVI Publishing Company West Port,
Connecticut Inc.

9.13 ANSWERS TO QUESTIONS

Check Your Progress I
1. Three methods are:
i. Home production
ii. Small scale producers
iii. Large scale manufacturers
2. The ice cream mix generally consists of milk, cream, sugar, egg and cornflavour.
It is usually made in small quantities for early domestic consumption. 39
Frozen Dairy Products 3. Many of the small-scale producers are ignorant of basic and simple methods of
hygienic production of ice cream. Consequently ice cream manufacturing by
them are invariably contaminated with disease producing microorganisms.
Consumption of such ice cream may lead to may type diseases.
4. The first step in the preparation of ice cream is to prepare ice cream mix with
suitable ingredients. This involves assembling of various ingredients. In order
to produce good ice cream both dairy ingredients and non-dairy ingredients
must be selected and combined so as to produce the desired body, texture and
the delicate flavour in the ice cream.
5. The ingredients which are rich in milk fat are:
1) sweet cream, 2) frozen cream, 3) plastic cream, 4) unsalted butter and 5)
butter oil
6. These are 1) skim milk, 2) skim milk powder, 3) condensed skim milk (plain
and sweetened) and 5) sweet cream buttermilk.
7. Sugar (cane sugar) is commonly used as sweetening agent in ice cream.
8. Sweetening agents like glucose syrup, corn solids, honey etc. can be used.
9. It improves the whipping ability of the ice cream mix. It also help prevent large
ice crystal formation during storage of ice cream.
10. It helps to emulsify fat in ice cream mix. It improves the whipping ability and
provide dry ice cream with smooth body and texture.
Check Your Progress 2
1. A balanced ice cream mix is one in which the proportions of the constituents
and ingredients are such that they will combine to produce an ice cream of
satisfactory quality.
2. The advantages of pasteurization are:
i. Renders the mix free of pathogenic bacteria.
ii. Brings into solution and aids in blending the ingredients of the mix.
iii. Improves flavour.
iv. Improves keeping quality.
v. Produces more uniform product.
3. Batch pasteurization- 68.5°C for not less than 30 minutes.
HTST pasteurization- 80°C for not less than 20 seconds.
4. i. Fat globule sizes are reduced
ii. No cream layer formation.
iii. More uniform ice cream with a smooth texture.
iv. Improves whipping ability.
v. Reduces ageing period.
vi. Reduces amount of stabilizer used in the ice cream mix.
40
5. Ageing refers to holding the ice cream mix at a low temperature for a certain Principle and Method of
Manufacture
period of time before freezing.
6. i. Fat is solidifies.
ii. Stabilizer swells and combines with water.
iii. Viscosity increases.
7. i. Improves body and texture of ice cream.
ii. Improves whipping ability of mix.
iii. Increases maximum overrun.
iv. Increases melting resistance.
Check Your Progress III
1. Two things are accomplished freezing of ice cream.
i. The mix is agitated to incorporate air in such a way as to produce and
control formation of small ice crystals. This is necessary to give smoothness
in body texture, palatability and satisfactory overrun in the ice cream.
ii. The mix is partially frozen to a certain consistency and drawn from freezer,
filled in packages and quickly transferred to cold storage rooms where
further freezing and hardening is completed without agitation.
2. Fast freezing is essential for smooth textured ice cream because ice crystals
that are formed quickly are smaller than those formed slowly.
3. Three types of freezer are:
i. Batch freezer
ii. Continuous freezer
iii. Soft serve freezer
4. Two main factors are:
i. Mechanical-depending on the type of freezer used
ii. Characteristic of mix-properties of mix.
5. Changes taking place are:
i. Lowering of the temperature of mix.
ii. Freezing portion of water of the mix.
iii. Incorporation air into the mix.
iv. Cooling of ice cream from the temperature, it is drawn from the freezer to
hardening room temperature.
6. It is the volume of ice cream obtained in excess of the volume of the mix taken.
It is usually expressed as “percent overrun”.
7. Factors need to be considered are:
i. Legal regulations enforced in the market.
ii. Total solids content of ice cream mix. 41
Frozen Dairy Products iii. Type of ice cream to be made (fruit/nut ice cream etc.)
iv. Selling price of ice cream.
v. Types of packages.
8. Attainable depends on the following points:
i. Types of ingredients used in the mix.
ii. Sharpness of scrapper blades.
iii. Speed of dasher.
iv. Volume of refrigerant passing over freezing chamber.
v. Temperature of refrigerant.

42