Universitatea "Vasile Alecsandri" din Bacău

Industrial Process and Raw

Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

2015-2016
Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

Index

History ........................................................................................................................................... 2
Ingredients .................................................................................................................................... 4
Raw Materials................................................................................................................................ 5
The Manufacturing Process........................................................................................................... 5
Blending the mixture ................................................................................................................. 6
Pasteurizing to kill bacteria ....................................................................................................... 6
Homogenizing to produce a uniform texture ........................................................................... 7
Cooling and resting to blend flavors ......................................................................................... 7
Flavoring the ice cream ............................................................................................................. 7
Freezing to soft-serve consistency ............................................................................................ 7
Adding fruit and sweetened chunks ......................................................................................... 8
Packaging and bundling the finished product ........................................................................... 8
Hardening .................................................................................................................................. 9
Quality Control .............................................................................................................................. 9
Biography .................................................................................................................................... 10

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

History

Our love affair with ice cream is centuries old. The ancient Greeks, Romans, and Jews
were known to chill wines and juices. This practice evolved into fruit ices and,
eventually, frozen milk and cream mixtures. In the first century, Emperor Nero
reportedly sent messengers to the mountains to collect snow so that his kitchen staff
could make concoctions flavored with fruit and honey. Twelve centuries later, Marco
Polo introduced Europe to a frozen milk dessert similar to the modern sherbet that he
had enjoyed in the Far East. The Italians were especially fond of the frozen confection
that by the sixteenth century was being called ice cream. In 1533, the young Italian
princess Catherine de Medici went to France as the bride of the future King Henry II.
Included in her trousseau were recipes for frozen desserts. The first public sale of ice
cream occurred in Paris at the Café Procope in 1670.

Frozen desserts were also popular in England. Guests at the coronation banquet of
Henry V of England in the fourteenth century enjoyed a dessert called cremefrez. By
the seventeenth century, Charles I was served creme ice on a regular basis. Eighteen-
century English cookbooks contained recipes for ice cream flavored with apricots,
violets, rose petals, chocolate, and caramel. Other early flavorings
included macaroon and rum. In early America, George Washington and Thomas
Jefferson were especially fond of ice cream. Dolley Madison was known to serve it at
White House state dinners.

Because ice was expensive and refrigeration had not yet been invented, ice cream was 2
still considered a treat for the wealthy or for those in colder climates. (In a note
written in 1794, Beethoven described the Austrians' fear that an unseasonably warm
winter would prevent them from enjoying ice cream.) Furthermore, the process of

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

making ice cream was cumbersome and time-consuming. A mixture of dairy products,
eggs, and flavorings was poured into a pot and beaten while, simultaneously, the pot
was shaken up and down in a pan of salt and ice.

The development of ice harvesting and the invention of the insulated icehouse in the
nineteenth century made ice more accessible to the general public. In 1846, Nancy
Johnson designed a hand-cranked ice cream freezer that improved production slightly.
The first documented full-time manufacturing of ice cream took place in Baltimore,
Maryland, in 1851 when a milk dealer named Jacob Fussell found himself with a
surplus of fresh cream. Workipg quickly before the cream soured, Fussell made an
abundance of ice cream and sold it at a discount. The popular demand soon convinced
him that selling ice cream was more profitable than selling milk.

However, production was still cumbersome, and the industry grew slowly until the
industrialization movement of the early twentieth century brought electric power,
steam power, and mechanical refrigeration. By the 1920s, agricultural schools were
offering courses on ice cream production. Trade associations for members of the
industry were created to promote the consumption of ice cream and to fight proposed
federal regulations that would call for selling ice cream by weight rather than volume,
and the disclosure of ingredients.

The Prohibition era proved to be very profitable for the ice cream industry. Denied
alcoholic beverages, many people ate ice cream instead. Breweries were often
converted to ice cream factories, although it is likely that some of the plants were
merely fronts for illegal liquor sales. Although the repeal of Prohibition in 1933 and the
ensuing depression slowed ice cream sales, the industry continued to grow. The movie
industry was especially instrumental in the promotion of ice cream and scenes
depicting stars enjoying the frozen concoctions were plentiful. Ice cream parlors
sprang up in every town and the parlor employee, the so-called soda jerk, developed
into a cultural icon.

After World War II, with raw materials readily available again, the ice cream industry
produced over 20 qt (19 1) of ice cream for each American per year. During the 1950s,
competition sprang up between the ice cream parlor and the drug store that sold
packaged ice cream. It was during this time that usage of lesser quality ingredients
increased. Many producers were adding very low percentages of butterfat and
pumping large quantities of air into the ice cream to fill out the carton. 3

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

The 1970s saw the development of gourmet ice cream manufacturers with an
emphasis on natural ingredients. People also became interested in making ice cream at
home. Upscale restaurants offer homemade ice cream on their dessert lists.

Ingredients
There is a wide range of ingredients and formulations (recipes) that can be used in ice
cream. The basic types of ingredients and their functions are briefly described below.

Milk fat provides creaminess and richness to ice cream and contributes to its melting
characteristics. The minimum fat content is 10% and premium ice creams can contain
as much as 16% milk fat. Sources of milk fat include milk, cream, and butter.

The total milk solids component of ice cream includes both the fat and other solids.
The other milk solids consists of the protein and lactose in milk and ranges from 9 to
12% in ice cream. The nonfat solids play an important role in the body and texture of
ice cream by stabilizing the air that is incorporated during the freezing process.
Sources of nonfat solids include milk, cream, condensed milk, evaporated milk, dry
milk, and whey.

Sweeteners are used to provide the characteristic sweetness of ice cream. Sweeteners
also lower the freezing point of the mix to allow some water to reamin unfrozen at
serving temperatures. A lower freezing point makes ice cream easier to scoop and eat,
although the addition of too much sugar can make the product too soft. Sweeteners
used include sugar (sucrose) and corn syrups.

Stabilizers are proteins or carbohydrates used in ice cream to add viscosity and control
ice crystallization. Over time during frozen storage small ice crystals naturally migrate
together and form larger ice crystals. Stabilizers help to keep the small crystals isolated
and prevent the growth of large crystals, which causes ice cream to be coarse, icy and
unpleasant to eat. Stabilizers used include alginates (carageenan), gums (locust bean,
guar), and gelatins.

Emulsifiers are used to help keep the milk fat evenly dispersed in the ice cream during
freezing and storage. A good distribution of fat helps stabilize the air incorporated into
the ice cream and provide a smooth product. Emulsifiers used in ice cream include egg
yolks and mono- and diglycerides.

A wide range of flavorings are used in ice cream. Flavorings include natural and 4
artificial flavors, fruit, nuts, and bulky inclusions such as chocolate chunks and candies.

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

Raw Materials

Today, ice cream is made from a blend of dairy products (cream, condensed milk,
butterfat), sugar, flavorings, and federally approved additives. Eggs are added for some
flavorings, particularly French vanilla. The broad guidelines allow producers to use
ingredients ranging from sweet cream to nonfat dry milk, cane sugar to corn-syrup
solids, fresh eggs to powdered eggs. Federal regulations do stipulate that each package
of ice cream must contain at least 10% butterfat.

The additives, which act as emulsifiers and stabilizers, are used to prevent heat shock
and the formation of ice crystals during the production process. The most common
additives are guar gum, extracted from the guar bush, and carrageenan, derived from
sea kelp or Irish moss.

Ice cream flavors have come a long way from the standard vanilla, strawberry, and
chocolate. By the 1970s, the International Association of Ice Cream Manufacturers had
recorded over 400 different flavors of ice cream. In an ever-expanding array of
combinations, fruit purees and extracts, cocoa powder, nuts, cookie pieces, and cookie
dough are blended into the ice cream mixture.

Air is added to ice cream to improve its ability to absorb flavorings and to facilitate
serving. Without air, ice cream becomes heavy and soggy. On the other hand, too
much air results in ice cream that is snowy and dry. The federal government allows ice
cream to contain as much as 100% of its volume in air, known in the industry as
overrun.

Makers of high-quality ice cream (sometimes known as gourmet ice cream) use fresh
whole dairy products, a low percentage of air (approximately 20%), between 16-20%
butterfat, and as few additives as possible.

The Manufacturing Process

Although ice cream is available in a variety of forms, including novelty items such as
chocolate-dipped bars and sandwiches, the following description applies to ice cream
that is packaged in pint and half-gallon containers. 5

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

Blending the mixture

 1 The milk arrives at the ice cream plant in refrigerated tanker trucks from local
dairy farms. The milk is then pumped into 5,000 gal (18,925 1) storage silos that
are kept at 36°F (2°C). Pipes bring the milk in pre-measured amounts to 1,000
gal (3,7851) stainless steel blenders. Premeasured amounts of eggs, sugar, and
additives are blended with the milk for six to eight minutes.

Pasteurizing to kill bacteria

 2 The blended mixture is piped to the pasteurization machine, which is

composed

of a series of thin stainless steel plates. Hot water, approximately 182°F (83°C),
flows on one side of the plates. The cold milk mixture is piped through on the 6
other side. The water warms the mixture to a temperature of 180°F (82°C),
effectively killing any existing bacteria.

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

Homogenizing to produce a uniform texture

 3 By the application of intensive air

pressure, sometimes as much as 2,000
pounds per square inch (141 kg per
sq cm), the hot mixture is forced through
a small opening into the homogenizer.
This breaks down the fat particles and
prevents them from separating from the
rest of the mixture. In the homogenizer,
which is essentially a high-pressure piston
pump, the mixture is further blended as
it is drawn into the pump cylinder on the
down stroke and then forced back out on
the upstroke.

Cooling and resting to blend flavors

 4 The mixture is piped back to the pasteurizer where cold water, approximately
34°F (1°C), flows on one side of the plates as the mixture passes on the
opposite side. In this manner, the mixture is cooled to 36°F (2° C). Then the
mixture is pumped to 5,000 gal (18,925 1) tanks in a room set at 36°F (2°C),
where it sits for four to eight hours to allow the ingredients to blend.

Flavoring the ice cream

 5 The ice cream is pumped to stainless steel vats, each holding up to 300 gal
(1,136 1) of mixture. Flavorings are piped into the vats and blended thoroughly.

Freezing to soft-serve consistency

 6 Now the mixture must be frozen. It is pumped into

continuous freezers that can freeze up to 700 gal (2,650 1) per hour. The
temperature inside the freezers is kept at -40°F(-40°C), using liquidammonia as
7
a freezing agent. While the ice cream is in the freezer, air is injected into it.
When the mixture leaves the freezer, it has the consistency of soft-serve ice
cream.

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

Adding fruit and sweetened chunks

 7 If chunks of food such as strawberry or cookie pieces are to be added to the

ice cream, the frozen mixture is pumped to a fruit feeder. The chunks are
loaded into a hopper at the top of the feeder. Another, smaller hopper, fitted
with a starwheel, is located on the front of the feeder. An auger on the bottom
of the machine turns the hoppers so that the chunks drop onto the starwheel in
pre-measured amounts. As the mixture passes through the feeder, the
starwheel pushes the food chunks into the ice cream. The mixture then moves
to a blender where the chunks are evenly distributed.

Packaging and bundling the finished product

 8 Automatic filling machines drop preprinted pint or half-gallon-sized

cardboard cartons into holders. The cartons are then filled with premeasured
amounts of ice cream at the rate of 70-90 cartons per hour. The machine then
places a lid on each cartons and pushes it onto a conveyer belt. The cartons 8
move along the conveyer belt where they pass under a ink jet that spray-paints
an expiration date and production code onto each carton. After the imprinting,

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

the cartons move through the bundler, a heat tunnel that covers each cup with
plastic shrink wrapping.

Hardening

 9 Before storage and shipping, the ice cream must be hardened to a

temperature of -10°F (-23°C). The conveyer system moves the ice cream
cartons to a tunnel set at -30°F (-34°C). Constantly turning ceiling fans create a
wind chill of -60°F (-5 1°C). The cartons move slowly back and forth through the
tunnel for two to three hours until the contents are rock solid. The cartons are
then stored in refrigerated warehouses until they are shipped to retail outlets.

Quality Control

Every mixture is randomly tested during the production process. Butterfat and solid
levels are tested. The bacteria levels are measured. Each mixture is also taste-tested.

Ice cream producers also carefully monitor the ingredients that they purchase from
outside suppliers.

Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău

Industrial Process and Raw Materials for Ice Cream
Raw Materials for Process Industries
Juan Cárdenas Acha

Biography

https://www.google.es/search?q=ice+cream+process&biw=1024&bih=499&tbm=isch&tbo=u&
source=univ&sa=X&ved=0ahUKEwjBwMmZ-LbKAhUHmw4KHTj8BIkQsAQIHg

https://www.google.es/search?q=ice+cream+process&biw=1024&bih=499&source=lnms&sa=
X&ved=0ahUKEwjv57Wb-LbKAhVIJw4KHVd4BuEQ_AUIBigA&dpr=1

https://www.uoguelph.ca/foodscience/book-page/ice-cream-manufacture

https://www.youtube.com/watch?v=poC7qic1aUE

http://www.milk.co.uk/page.aspx?intPageID=389

http://www.benjerry.com/flavors/how-we-make-ice-cream

https://www.linkedin.com/pulse/general-steps-ice-cream-processing-william-wang

http://drinc.ucdavis.edu/dfoods9_new.htm

http://www.che.cemr.wvu.edu/publications/projects/multiscale/icecream.pdf

http://science.howstuffworks.com/innovation/edible-innovations/ice-cream1.htm

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Universitatea "Vasile Alecsandri" din Bacău | Calea Mărășești 158, Bacău