ICE CREAM

REKHA S. SINGHAL HEAD OF FOOD ENGINEERING AND TECHNOLOGY DEPT. INSTITUTE OF CHEMICAL TECHNOLOGY, MATUNGA, MUMBAI - 400 019

DEFINITION
Ice cream may be defined as a ,frozen dairy product made by suitable blending and processing of cream and other milk products, together with sugar and flavor, with or without stabilizer and color, and with the incorporation of air during the freezing process. FSSAI Definition with specifications : It is the frozen product obtained from cow or buffalo milk or a combination thereof or from cream, and the other milk products, with or without the addition of cane sugar, eggs, fruits, fruit juices, preserved fruits, nuts, chocolate, edible flavors and permitted food colors, where Permitted emulsifiers & stabilizers 0.5%. Milk fat 10% or Milk fat 8% if fruits &/or nuts are included. Milk protein 3.5%. Total solids 36%. starches 5%, with proper declaration on the label.

CLASSIFICATION
Plain Ice-cream -Color and flavoring ingredients together amount to less than 5% of the volume of unfrozen ice cream. e.g. vanilla, coffee ice creams. Chocolate Ice-cream -Ice cream flavored with cocoa or chocolate. Fruit & Nut -Containing fruits like strawberry, apricot, mango, banana etc. with/without flavors, and nuts such as almonds, pistachio, walnuts, cashew nuts etc. Ices -Made from fruit juice, sugar and stabilizer with/without adding fruit acid, color, flavor (no dairy products) & frozen to consistency of ice cream. Sherbet -Made from fruit juices, sugar, stabilizer, and milk products. Similar as ices where all or a part of water is replaced by milk. Softy Ice cream -Sold as drawn from the freezer without hardening.

COMPOSITION
Constituents Milk fat Milk solids-non-fat (MSNF) Sugar Economy Ice Cream 10.0 10.0-11.0 13.0-15.0 Good Average Ice Cream 12.0 11.0 15.0

Stabilizer & Emulsifier

Total solids

0.30-0.50
35.0-37.0

0.30
37.5-39.0

Table.1 Approximate Composition of Commercial Ice Cream

FOOD & NUTRITIVE VALUE

An excellent source of energy having 2-3 times more fat content than that of milk, with slightly more protein content. Also, it may contain fruits, nuts, eggs, and sugar which enhances food value. Rich source of Ca, P, and other minerals but not Fe !! Rich in vitamins such as A, B2, B3, E and vitamin C (not in milk but in fruits).

ROLE OF THE CONSTITUENTS

Milk Fat Enriches and mellows the ice cream, giving it a full, rich creamy flavor. Contributes to body & melting resistance, producing smooth texture. A costly ingredient, impairs whipping ability, and has high calorific value.

Milk Solids-Non-Fat Known as serum solids consisting of milk protein, milk sugar & mineral matter. Improves body & texture, have high food value & are inexpensive. Lactose contributes to sweetness, proteins make ice cream more compact & smooth. Has less impact on the smell. Should be added as largely as possible without risking the danger of sandiness, & salty or cooked flavor.

ROLE OF THE CONSTITUENTS

Sugar Desired sweetening effect is produced only by sucrose. Improves texture, enhances flavor but main function is to increase acceptability. Cheapest source of total solids. Stabilizers Prevents formation of ice crystals especially during storage. Effective in texture smoothening, & giving body to the product. No significant effect on flavor and food value.

Emulsifier For improving upon and providing a uniform whipping quality to the mixture, with reduced whipping time. Produces drier ice cream with smooth body & texture. May result in excess body and decreased melting resistance.

ROLE OF THE CONSTITUENTS

Flavor & Color Flavor increases acceptability and color its aesthetic quality. Harsh/intense flavors should be avoided.

PROPERTIES OF MIX
Viscosity Essential for proper whipping and & retention of air. Two types are, Apparent- which is at thickened condition Basic- which remains after the apparent viscosity disappears with agitation.

It is in turn influenced by
1.Composition:-Fat, stabilizers increases viscosity but not as to a great extent as gelatin, if present. -Sugar, whereas, decreases viscosity.

PROPERTIES OF MIX
2.Kind & Quality of Ingredients:-Whether the ingredient is a source of fat, serum-solids, sweetening, etc. -Heat & salts (Ca, Na, etc.) affect viscosity due to their effect on milk proteins. 3.Processing & Handling of the Mix:-Pasteurization, homogenization decreases viscosity. -Aging causes increase in it because of solidification of the butter fat and hydration of proteins. 4.Total Solid Concentration:-General behavior of viscosity is to increase with solid content but it in turn depends upon type and source of solids. e.g. fat causes slight increase than gelatin. -Increase in viscosity depends on physical state of solids. e.g. proteins coagulated or not.

PROPERTIES OF MIX
5.Temperature:Lowering the temperature results in increased viscosity. Desirable values of ice cream viscosity are not yet determined with the fact however that it can range between 50-300 centipoise.

PROPERTIES OF MIX
Acidity & pH Depends upon serum solids content, and calculated as,
% Acidity of mix= % acidity of milk

% serum solids in mix % serum solids in milk

Thumb rule :- Multiply serum solids by 2 and divide by 100. Normal pH of mix = 6.3 High acidity indicates presence of lactic acid. Its undesirable, as it contributes to excessive mix viscosity, decreased whipping rate, an inferior flavor & a less stable mix. Neutralization can be done by NaHCO3, Na2CO3, Ca(OH)2, NaOH etc. in this case. However, over neutralization produces flat flavor & dull (greyish) color.

PROPERTIES OF MIX
Mix stability Refers to resistance to separation by the milk proteins by coagulation or precipitation in the mix. Otherwise ice cream will have curdled appearance. Various factors responsible for this defect are
o o o o o o o Mix acidity Low citrate and phosphate content High Ca, Mg content high homogenizing pressure High heat treatment (pasteurization) Low aging time (poor hydration) Destabilizing effect of freezing

Particle size, charge & degree of hydration is important; most stable mix particle is hydrophilic suspension as it is charged & hydrated.

PROPERTIES OF MIX
Specific Gravity Varies with its composition Ranges from 1.05-1.12 Sp. Gravity @ 160C =
100 % fat 0.93 % Sugar % MSNF % Stabilizer 1.58 %Water 1

Surface Tension Studies indicates that increasing surface tension than that of a freshly prepared mix is difficult. Emulsifiers however can readily decrease it, but lowering it to very less value will result in excessive whipping rates, fluffy short body, & shrinkage defects. Normally it varies from 48-50 dynes.cm2

PROPERTIES OF MIX
Freezing Point Depends on soluble constituents & varies with its composition. Sugar, milk sugar, milk salts and externally added substances (which are in true solution) affects it directly. Indirect effect is due to fat, proteins & those which are not in true solution. Glucose depresses it for 2 times than sucrose. Average mix has freezing point of 27.50F. Whipping rate High whipping rate means the ability to whip rapidly to a high overrun. Not related to viscosity however, it is hypothesized that tensile strength & strength of lamella (i.e. walls around the air cells) has measure contribution. Small fat globules & less clumping High whipping ability

Selection of ingredients Figuring the mix Making the mix Pasteurizing the mix (680C/1550F for 30 min.) Homogenizing the mix (1st stage-2500psi, 2nd stage- 500 psi) Cooling & Aging the mix (0-40C) Freeing the mix (-4 to -50C) Fig.1 Schematic representation Of Ice cream Manufacture Packaging of ice cream

Handling & storage (-23 to -290C)

SELECTION OF INGREDIENTS
Dairy products 1. Source of fat
o o o o Sweet cream (mostly used) Frozen cream Unsalted butter Butter oil

2. Sources of MSNF
o o o o Skim milk powder (generally used) Skim milk Condensed skim milk Sweet cream butter milk

3. Sources of both fat & MSNF

o o o o Whole milk Whole milk powder Condensed whole milk Evaporated milk

SELECTION OF INGREDIENTS
Non-Dairy products 1. Sweetening Agents
o o o o o o Sucrose (most common) Dextrose (corn sugar) Corn syrup solids (dextrose + maltose) Corn syrup Invert sugar (glucose + fructose) saccharin (in diabetic ice creams)

2. Stabilizers
o Gelatin (animal source) o Na- alginate (vegetable origin & hence widely used) o Guar gum etc.

3. Emulsifiers
o Mono- or di-glycerides of fat forming fatty acids

SELECTION OF INGREDIENTS
4. Flavors
o o o o o o Vanilla (most popular) chocolate strawberry pineapple banana mango

5.

Colors
o Yellow, pink green etc.

6.

Egg solids
o Yolk solids improve whipping ability

7.

Fruit and Nuts

o Apple, banana, mango, pineapple, grape, almond, pistachio, cashew nut, walnut, groundnut

FIGURING THE MIX

Important step for ice cream to assure legal standards. Two types of mix can be thought of:
o Simple mix:- requires less calculation, each ingredient supplies one constituent. o Complex mix:- difficult to figure, at least one constituent is obtained from two or more products.

Before a mix can be calculated, it is necessary to:

1. 2. 3. 4. Decide upon the composition of the mix to be made; Decide on the amount of mix to be made in the batch at one time; Choose from the available ingredients those that will give the desired quality characteristics & composition at the lowest cost; Be familiar with the composition (i.e.) analysis of ingredients to be used.

NUMERICAL
Prepare an ice cream mix containing 10% fat, 11% serum solids, 14.5% sugar, & 0.3% stabilizer. Given : whole milk testing 6.8% fat, 9.6% serum solids, cream testing 40% fat & 5.4% serum solids, skim milk powder testing 0.5% fat & 97% serum solids, sugar & stabilizer.
o HINT:- Try to form mass balance equations for total fat, serum solids, & total mass balance. Then solve these three equations to find three unknowns X= while milk required Y= cream required Z= skim milk powder required.

NUMERICAL
SOLUTION
X= whole milk required Y= cream required Z= skim milk powder required Hence, X (6.8/100) + Y(40/100) + Z(0.5/100) = 10..mass balance for fat X (9.6/100) + Y(5.4/100) + Z(97.0/100) = 10...mass balance for serum solids X + Y + Z + 14.5 + 0.3 = 10...overall mass balance

Solving the above, we get X=67.9 Y=13.4 Z=3.9

MAKING THE MIX

Selection of good, wholesome ingredients is important. These are then mixed in a vat where they are heated to facilitate dissolving, blending & pasteurizing. Order of mixing ingredients is most important & is as follows:
All liquid ingredients are first taken in vat; agitation & heating is started. Dry ingredients are mixed thoroughly for uniformity. Dry ingredients are then added while continuing agitation, before 490C. Gelatin if used, is best added after it is thoroughly mixed with equal volume of sugar and before liquid reaches 490C (1200F). o Na- alginate should be added after mix crosses 660C of temperature. o If butter, plastic/frozen cream are used, they are cut into small even pieces and then added. o Coloring & flavoring materials are added when the mix is frozen. o o o o

PASTEURIZING THE MIX

Important and mandatory to destroy all pathogenic or disease producing bacteria.

Homogenization can be bets accomplished at the pasteurization temperature level.

Advantages are:
o o o o o It renders the mix completely free of pathogenic bacteria. It dissolves and helps to blend the ingredients. Improves flavor. Improves keeping quality. Produces a more uniform product.

Batch method : - 68.50C (1550F) for not less than 30 min. HTST method : - 80.00C (1750F) for not less than 25 sec.

HOMOGENIZING THE MIX

Main purpose is to make a permanent & uniform suspension of the fat by reducing the size of flat globules to a very small diameter (< 2 microns). Advantages are:
o o o o o o Prevents fat separation during aging. Produces more uniform ice cream with smoother texture. Improves whipping ability. Shortens ageing period. Decreases the risk of churning occurring in the freezer. Leads to the use of slightly less stabilizer

HOMOGENIZING THE MIX

Homogenization temperature ranges from 63-770C. Low process temperatures should be avoided as it promotes formation of clumps of fat globules, increases viscosity & freezing time. For 1 step homogenization, pressure of 2500-3000psi is applied. 2 step homogenization uses 2500psi for the 1st step, & then 500psi in 2nd stage.

COOLING & AGEING THE MIX

Immediate cooling after homogenization to 0-50C. Ageing refers to holding the mix at a low temperature for a definite time before freezing. Ageing temperature should not exceed 50C. Commercial ageing time is 3-4 hrs. It results in,
o o o o Improved body & texture. Increased whipping capacity. Increased maximum overrun. Improved melting resistance.

FREEZING THE MIX

The process can be divided into two parts: 1. The mix, with the proper amount of color & flavoring materials added at the freezer, is quickly frozen while being agitated to incorporate air so as to produce & control the formation of small ice crystals.

2.

After partially freezing to a certain consistency, it is drawn from the freezer into packages & quickly transferred to cold storage rooms, where the freezing & hardening process is completed without agitation.

Changes taking place during the freezing process

Lowering the temperature of the mix from ageing temperature to freezing point. Freezing a portion of water in the mix (after sensible heat is removed). Incorporation of air into the mix. Cooling ice cream from the temperature at which it is drawn from the freezer to hardening room temperature. Note: Freezing causes pure ice crystals to form. Hence, sugar & other solutes become more concentrated in remaining liquid water. Latter phenomenon causes further decrease in freezing point. Process thus continues until solute concentration is so great that further freezing will not occur. Thus all the water does not freeze even after long periods in the hardening room.

OVERRUN IN ICE CREAM

Defined as the volume of ice cream obtained in excess of the volume of the mix. This is mainly due to incorporation of air & expressed in %.
(volume of ice cream)- (volume of mix) *100 (volume of mix) (weight of unit volume of mix) - (weight of unit volume of ice cream) *100 (weight of unit volume of ice cream)

% overrun

OR
% overrun

Amount of air incorporated depends upon mix composition, the way it is processed & regulated. It gives proper body, texture & palatability necessary to a good quality product.

OVERRUN IN ICE CREAM

However very high overruns produce a snowy, fluffy, unpalatable ice cream. To have a uniformity in overrun, we should ensure:
o o o o o Uniformity in refrigerant temperature & flow rate of refrigerant. The use of overrun testers. Uniform make etc., of freezer for the operator. % No too many freezers per operator. Hopper system for filling containers if batch freezers are used.

Products Ice cream, packaged Ice cream, bulk Softy ice cream

% Overrun 70-80 90-100 30-50

Table.2 % Overrun in ICE CREAMS

PACKAGING OF ICE CREAM

After freezing, ice cream is drawn into containers to give it final desired shape & then goes for packaging. Gives protection against moisture loss, temperature fluctuations, avoids recontamination. Ice cream packages are of two types: Multi-serving:o o For seldom use e.g. tinned-steel cans. They are cleaned, sanitized & used repeatedly.

1.

2.

Single-serving:o o o o Very popular. Bulk ice cream packed in fiber board cartons coated with wax or polythene-wax blends for protection against moisture & oxygen. Compete plastic cylindrical containers with a recloseable lid are also used. They are cleaned, sanitized & used repeatedly.

HARDENING & STORAGE OF ICE CREAM

Its a continuation of freezing process without agitation until temperature of ice cream reaches -180C. Semisolid consistency changes to solid. Generally carried out for 12hrs of duration, which also depends upon
o o o o o o Size & shape of ice cream package. Temperature & speed of cool air circulation. Section of hardening room. Temperature of ice cream drawn from the freezer. Composition if mix. % overrun.

Hardening Systems Hardening rooms

Temperature maintained (0C) -12 to -45

Hardening tunnels Hardening cabinets

-34 to -45 -23 to -26

Table.3 ICE CREAM Hardening Systems

PRECAUTIONS DURING HARDENING/STORAGE

Precautions to be observed in operations of hardening/storage rooms: Provide facilities for calling for aid, operator should not accidently be trapped inside; Keep both an axe & a sledge hammer in a definite place just inside the door; Avoid fluctuations in temperatures.

DISTRIBUTION OF ICE CREAM

Product should reach the retailer at the same temperature at which he is going to store it. Dry ice refrigeration uses solid CO2 (freezing point= -780C), which is cut into pieces & then placed around the packages inside an insulated packer.

Advantages of using solid CO2 are,

o o o o o o o Its neither moist nor messy. The package is neat in appearance. Does not waterlog the insulation, & It is very light. Expensive & limited availability. Loss during handling & storage. Danger of burns to handler.

Demerits are,

DISTRIBUTION OF ICE CREAM

Refrigerated trucks are commonly used means of transportation in developed countries. Trucks are refrigerated overnight, then filled with packaged product the following morning. Frozen brine jacketed metal containers (called as eutectic pads), contains CaCl2 solution, & are refrigerated in same brine tank whose Sp. gravity is 1.26, at a temperature of -320C. Containers attain a temperature of -210C & are then placed around the packaged ice cream.

SOFT ICE CREAM (SOFTY)

Marketed in soft conditions & is ready to consume after drawing from the freezer.

Drawn at around -8 to -70C from the freezer.

The overrun ranges from 30% to 50%.
Constituent Fat Milk-solids-non-fat Percentage (%) 3-6 11-14

Sugar Stabilizer & Emulsifier

12-15 0.4-0.6

Table.4 Composition of Soft Ice Creams

JUDGING & GRADING OF ICE CREAM

Item Flavor Body & Texture Bacteria Color & package Melting quality Perfect score 45 30 15 5 5

Table.5 Score Card of Ice Creams

FLAVOR

DEFECTS IN ICE CREAM, CAUSES & PREVENTION

Causes Excessive flavor addition Inadequate flavor addition Using sour dairy products, slow mix cooling, & high temperature storage Use of low quality ingredients especially flavors, dairy products Overheating during pasteurization Prevention Addition of correct amount of flavor Addition of correct amount of flavor Use fresh & sweet dairy products, prompt & efficient cooling of milk & storing mix @ 0-50C Use true flavor extracts, fresh & sweet dairy products Proper & controlled heating during the same

Name of defect High Low Acid/sour

Bitter Cooked

Table.6 Defects In Ice Creams, their Causes, & Prevention

FLAVOR

DEFECTS IN ICE CREAM, CAUSES & PREVENTION

Causes Adding of inadequate sugar Addition of not-so-typical (ice cream) flavor Fat hydrolysis due to lipase action in individual fat rich ingredients/mix Fat oxidation due to direct contact with Cu/Fe, sunlight Prevention Addition of correct amount of sugar Addition of typical flavor Inactivation of lipase by proper pasteurization

Name of defect Flat Unnatural Rancid

Oxidized/oily/ metallic/tallowy

Storage in tinned /Al alloy/Stainless steel vessels

Table.7 Defects In Ice Creams, their Causes, & Prevention

BODY

DEFECTS IN ICE CREAM, CAUSES & PREVENTION

Causes Low solids &/or stabilizers, high overrun, improper homogenization Low overrun, high sugar &/or content Prevention Optimum solid/stabilizer content, correct overrun, proper homogenization Optimum overrun, sugar & stabilizer content

Name of defect Crumbly

Soggy

Weak

Low solid &/or stabilizer content

Optimum solid &/or stabilizer content

Table.8 Defects In Ice Creams, their Causes, & Prevention

Texture

DEFECTS IN ICE CREAM, CAUSES & PREVENTION

Causes Inadequate homogenization Low solids &/or stabilizers, long storage inadequate ageing, slow freezing & hardening, heat shock, Excessive overrun, low solid content, excessive emulsifiers High MSNF/lactose content, temperature fluctuation in retail cabinet, long storage period Prevention Proper homogenization Optimum solids &/or stabilizers, adequate ageing, rapid freezing & hardening, avoiding heat shocks, short storage Optimum overrun, optimum solid & emulsifier content Optimum MSNF/lactose content, avoiding temperature fluctuations in retail cabinets, short storage

Name of defect Buttery Course/Icy

Fluffy Sandy

Table.9 Defects In Ice Creams, their Causes, & Prevention

Melting Quality

DEFECTS IN ICE CREAM, CAUSES & PREVENTION

Causes Using high acid mix Excessive overrun, excessive emulsifiers Excessive stabilizer content, inadequate homogenization Prevention Using fresh, sweet mix Optimum overrun & emulsifier content Optimum stabilizers, adequate homogenization

Name of defect Curdy meltdown Foamy meltdown Slow melting

Table.10 Defects In Ice Creams, their Causes, & Prevention

Color

DEFECTS IN ICE CREAM, CAUSES & PREVENTION

Causes Wrong color Prevention Proper color

Name of defect Unnatural

Table.11 Defects In Ice Creams, their Causes, & Prevention

Miscellaneous
Causes Prevention

Name of defect

Shrinkage

Temperature fluctuations during storage, excessive overrun, rough transportation

Constant storage temperature, optimum overrun, avoid rough transportation

Table.12 Defects In Ice Creams, their Causes, & Prevention

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