How to Start Ice Cream Manufacturing Business, Flavoured Ice cream, Production Process, Flavored Ice cream Making, Packaging
The document outlines the growing ice cream manufacturing business in India, highlighting its seasonal nature and evolving consumer perceptions that have contributed to a significant growth in the market. With a projected increase in industry value from Rs 45 billion in 2013 to Rs 70 billion by 2018, the document details the production process, composition, handling, and categorization of ice cream along with essential ingredients and market trends. It serves as a comprehensive resource for entrepreneurs and professionals in the ice cream sector, covering topics from manufacturing processes to flavors and microbiology.
How to Start Ice Cream Manufacturing Business, Flavoured Ice cream, Production Process, Flavored Ice cream Making, Packaging
1.
How to Start
IceCream
Manufacturing Business
Flavoured Ice cream, Production Process,
Flavored Ice cream Making, Packaging
2.
Ice-cream is oneof the fastest growing food categories in India. Notably, the business is seasonal
in nature with April to June being the peak season and November to January the lean months.
Sales slacken during the monsoons also. India is the most rapid growing ice cream market
globally, with icecream treatsfastbecominga partofIndianculture.Indianconsumersareturning
into regular patrons of ice cream parlours, helping to fuel greater interest in packaged offerings in
thecountry.
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Introduction
Ice cream parlours are a booming business in India, and this popularity is making its way to
retail.
3.
In value terms,the organised segment of India's Rs 3,000-crore ice cream market has been growing at 19.5
per cent a year for the last five years. Many established food and lifestyle trends, such as limited edition,
indulgent, natural and premium ingredients have led to the establishing of ice cream ranges under claims of
'premium'.
The ice-cream market has been through an evolution wherein the category has grown in shape and form
right from consumer perception to the products and services being offered. Ice-cream, which was considered
an indulgent category in the past, has now evolved to a stage where it is largely and happily perceived as a
snackingoptionbyconsumers.
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4.
This change inperception has come about thanks to increasing disposable incomes and
greater discretionary spending. Also, the growing reach of the media has allowed
operators in this category to expand their range and recall value. The change in the
perception of consumers has allowed the category to grow in volume. Ice-cream, as a
category,hasbeen growing atahealthyCAGR of~10-15%.
The overall ice cream market is estimated at over 250 mn litre valued at around Rs. 17
bn.
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5.
Nearly a fourthof the market by volume at 50 mn litres is in the organized sector with
players like Amul, Hindustan Unilever (HUL), Mother Dairy, Vadilal having a major
share.In valueterms,theorganisedsectorhasanoverall marketofoverRs.10bn. The
PHD Chamber of Commerce and Industry has projected that the size of ice cream
industry, estimated at Rs. 45 bn in 2013 is likely to jump to Rs. 70 bn by 2018.The
domestic ice cream industry would grow at the compounded growth rate (CAGR) of
about 25% in future with high profit margins ranging between 15 to 20% to reach the
project level since its per capita consumption has gone up at 300 ml against world
averageof2.3 litre.
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7.
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Ice Cream isa favourite food of millions around the world. It is a frozen mixture of a
combination of component of milk, sweeteners, stabilizers, emulsifiers and flavours. Ice
cream is a palatable, nutritious and relatively inexpensive food. No other food enjoys so
much popularity and has as attractive a form and appeal as ice cream. Ice cream is
composed of the mixture of food materials, such as milk products, sweetening materials,
stabilizers, emulsifiers, flavours or egg products which are referred to as ingredients. Milk
fatis ofmajorimportancein ice cream.
8.
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It contributes richflavor to the ice cream, is a good carrier for added flavor compounds and promotes
desirable tactual qualities. Stabilizers are used to prevent the formation of objectionable large ice crystals in
ice cream. Emulsifiers are used to produce ice cream with smoother body and texture, to impart dryness and
to improve whipping ability of the mix. Flavour is considered the most important characteristics of ice cream.
It hastwocharacteristics;typeandintensity.
Classification of ice cream may be based on commercial terms commonly agreed upon or
onregulatorycompositionrequirementsorflavorlabeling standards.
9.
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Commercially ice creamis classified as plain ice cream, chocolate, fruit, nut, frozen custard, confection, bisque,
puddings, mousse, variegated ice cream, Neapolitan, ice milk, lacto, novelties, frappe etc. The basic step of
production in manufacturing ice cream are composing the mix, pasteurization, homogenization, cooling,
ageing, flavouring,freezing,packaging,hardening,storage,loadingoutproductsandcleaning ofequipments.
Ice cream can be mass produced and thus is widely available in developed parts of the
world. Ice cream can be purchased in large cartons from supermarkets and grocery
stores, in smaller quantities from ice cream shops, convenience stores, and milk bars,
andin individualservings fromsmall cartsorvansatpublicevents.
10.
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Ice cream isexpected to continue to expand robustly in India as purchasing power
increases and as manufacturers invest in expanding the availability of ice cream in
small stores.
Some of the fundamentals of the book are composition of ice cream mixes, the role of
the constituents, diet science and classification of ice cream, caloric content of ice
cream and related products, milk fat content of ice cream, classification of ice cream
and related products, artificially sweetened frozen dairy foods, ingredients of ice cream
roles and properties, effect of sweetener on freezing point, influence on ice crystal size
andtexture,
11.
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flavour and colourmaterials and preparation, ice cream mixer preparation
processing and mix calculations, the freezing process, the freezing point of
ice cream mixes, ice cream handling, cleaning and sanitation, varieties,
novelties and specials etc.
It is a comprehensive book which covers all the aspects of manufacturing
of ice cream in various flavours. The book is meant for entrepreneurs,
technocrats, professionals, researchers, dairy technologists etc.
12.
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Table of Contents
1.ICE CREAM-HISTORY AND DEVELOPMENT HISTORICAL BACKGROUND
2. COMPOSITION OF ICE CREAM MIXES
COMPOSITION
THE ROLE OF THE CONSTITUENTS
Milk Fat
Milk Solid Not Fat (MSNF)
Sweetener Solids
Egg Yolk Solids
Stabilizers
Emulsifiers
Total Solids
Water and Air
Flavour
13.
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IMPORTANCE OF FLAVOURCOLOUR
OPTIONAL INGREDIENTS
THE BALANCED MIX
Conditionsm, That Limit the Balancing of a Mix
Mix Properties
Mix Stability
3. DIET-SCIENCE AND CLASSIFICATION OF ICE CREAM
NUTRITIONAL VALUE
Energy Value and Nutrients
Energy Content of Food
CALORIC CONTENT OF ICE CREAM AND RELATED PRODUCTS
Energy Content of Ice Cream and Related Products
Protein Content of Ice Cream
MILK FAT CONTENT OF ICE CREAM
MILK FAT CONTENT
CARBOHYDRATES
Carbohydrates in Ice Cream
Minerals
14.
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MINERALS IN ICECREAM
VITAMINS
Vitamins in Ice Cream
PALATABILITY AND DIGESTIBILITY OF ICE CREAM
CLASSIFICATION OF ICE CREAM AND RELATED PRODUCTS
Commerical Grouping of Ice-Cream and
Related Products Plain Ice Cream
Chocolate
Fruit
Nut
Frozen Custard
Confection
Bisque
Puddings
Mousse
Variegated Ice Cream
Neapolitan
Ice Milk
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4. INGREDIENTS OFICE CREAM-ROLES AND PROPERTIES
SOURCES OF MILK SOLIDS NOT FAT
Milk
Milk Products used in Ice Cream Sources of Fat
Skim Milk
Butter Milk
Concentrated Skim Milk
Sweetened Condensed Milk
Skimmed Milk Powder
Special Commercial products
Whey Protein Concentrate
Mineral Salts
Unsalted Butter
Sweeteners
SOURCES OF SUGAR
Effect of Sweetener on Freezing point
Sucrose
Corn Sweeteners and Related Ingredients
17.
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Dextrose
Corn Syrup
Dried CornSyrup
Invert Sugar
Honey
Other Sweeteners
Nonnutritive Sweeteners
EGG AND EGG PRODUCTS
Fat Replacers
Sugar Alcohols
Syrups
STABILIZERS AND EMULSIFIERS
Function of Stabilizers
Influence on Ice Crystal Size and Texture
Shape and Body Characteristics
Retention of Air
Role in Fat Destabilization
Control of Sandiness
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Polyglycerol Esters
Fruit AcidEsters
Ethoxylated Mono and Diglycerides
Egg Yolk Solids
Function of Emulsifiers
Whipping Ability and Overrun Control
Stiffness and Dryness
Secondary Effect of Emulsifiers
Selection of Stabilizer and Emulsifier
Processing the Cocoa Beans
5. FLAVOURS AND COLOURS-MATERIALS AND PREPARATION
FLAVOURS FOR FROZEN DESSERTS
VANILLA
Imitation Vanilla Flavourings
Consistency in Vanilla Quality
Vanilla Ice Cream
20.
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CHOCOLATE AND COCOA
ChocolateIce Cream
Freezing Characteristics
Chocolate Confections
FRUITS IN FROZEN DESSERTS
Fresh Fruit
Candied and Glaced Fruits
Dried Fruits
PROCEDURES AND RECIPES
Strawberry Ice Cream
Raspberry Ice Cream
Peach Ice Cream
Cherry Ice Cream
Ice Cream with Complex Flavours
Sugar Free
NUTS
SPICES AND SALT
COLOUR IN FROZEN DESSERTS
FLAVOURING LOWFAT AND NONFAT ICE CREAM
21.
6. ICE CREAMMIXER-PREPARATION PROCESSING AND MIX CALCULATIONS
PREPARATION OF THE MIX
Combining the Ingredients
PASTEURIZATION OF THE MIX
Pasteurization Renders the Mix
There are Two Basic Methods of Pasteurization
Homogenizing the Mix
Physical Effect of Homogenization
Homogenizing Temperature
Location of Homogenizer
Pressure for Homogenization
Care of the Homogenizer
Cooling the Mix
Ageing the Mix
Making the Mix in a Vaccum pan
Forewarming
Concentrating the Dairy Products
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22.
Weighing the ConcentratedDairy Products
Adding Sugar and Stabilizer, and Pasteurizing
FLAVOURING MIXES
Cooling, Standardizing and Ageing
PACKAGING MIXES FOR SALE
CALCULATION OF ICE CREAM MIXES
The Importance of Calculations
MATHEMATICAL PROCESSES MOST FREQUENTLY USED
Methods of Calculating Mixes
Pearson Square Method
Arithmetical Method
CALCULATING MIXES WITH THE SERUM POINT METHOD
MIX DECISIONS
SIMPLE MIXES
COMPLEX MIXES
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23.
7. THE FREEZINGPROCESS
THE FREEZING POINT OF SOLUTIONS
The Frezzing Point of Ice Cream Mixes
PREFREEZING TESTS
FREEZING OPERATIONS
CHANGES THAT TAKE PLACE DURING THE FREEZING PROCESS
REFRIGERATION NEEDED TO FREEZE ICE CREAM
TYPES OF FREEZERS
The Continuous Freezer
The Refrigeration System
Operating the Continuous Freezer
Batch Freezer
Freezing Procedure for Batch Freezers
8. ICE CREAM HANDLING
CONSIDERING THE PACKAGE
REQUIREMENTS FOR PACKAGING
Paper
Substance of Paper
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24.
Stiffness
Ink
Wax
Adhesive
Wax Content
Odour andTaint
Toxicity
Resistane to Deep Freezing
Leak Proofness
Paper Board
Thickness
Wax Content
Stiffness
Ink
Wax Quality
Adesive
Odour and Taint
Manufacturer's Joint
THE PACKAGING OPERATION
Packaging for Direct Sale to Consumers
Economy in Packaging Operations
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25.
THE HARDENING PROCESS
FactorsAffecting Hardening Time
Types of Hardening Facilities
Rapid Hardening Systems
HANDLING, STORING AND SHIPPING
Shipping with Dry Ice
Quality is the Goal
9. CLEANING AND SANITATION
PRINCIPLES OF CLEANING
CLEANING
Rinsing
Removal of Sediment
Removal of Fat
Removal of Proteins
Removal of Mineral Deposits
After Rinsing with Clean Water
Cleaning Agents
Alkalis
Acids
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26.
Water Chelating Agent
Emulsifiersand Wetting Agents
Protective Substances
Composite Cleaning Agents
Alkaline Composites
SANITIZATION OF EQUIPMENT
SANITARY ENVIRONMENT
HYGIENIC PERSONNEL
TEST OF THE FINISHED PRODUCT
Hazard Analysis and Critical Control Points (HACCP)
HACCP Principles
SUMMARY
10. DEFECTS AND GRADING OF ICE CREAM
FLAVOUR DEFECTS
Flavouring System
SWEETENER SYSTEM
BODY AND TEXTURE DEFECTS
Defects of Body
Defects of Texture
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27.
COLOUR
PACKAGE
MELTING QUALITY
Defects ofMelting Quality
Defects in Ice Cream, their Causes and Prevention
EVALUATING FROZEN DESSERTS
SCORING METHODS
ICE CREAM CLINICS
11. VARIETIES, NOVELTIES AND SPECIALS
PLAIN ICE CREAM
Formula
Variations
Vanilla
Strawberry
Rose
Coffee
Caramel
Mint
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Tutti-Frutti
Banana Nut
VARIEGATED ORRIPPLED ICE CREAM
Probiotic Ice-Cream
Manufacture of Preobiotic Ice-Cream
LABELLING OF PROBIOTIC FOODS
NEW DIET SCIENCE FOR ICE CREAM
SORBET AND ICE CREAM
Manufacturing Procedure
Ice Cream Mix
Sorbet
Freezing
KULFI
Product Description
Technology
Innovations
Formulation of Kulfi
Optional Dairy Ingredients for Kulfi and Frozen Desserts
Sweet Fresh Cream and Fresh Milk
Frozen Cream
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31.
Fluid Whole andSkim Milk
Plain Condensed Skim Milk
Plain Condensed Whole Milk
Sweetened Condensed Whole or Skim Milk
Packaging
Physico-Chemical Aspects
Shelf Life
DECORATION
12. ICE CREAM MICROBIOLOGY
ICE CREAM AS A CARRIER DISEASE
THE BACTERIAL COUNT OF ICE CREAM
Mix Ingredients as a Source of Bacteria
Dairy Products as a Source of Bacteria
Sugar as a Source of Bacteria
Stabilizers as a Source of Bacteria
Flavouring Materials as a Source of Bacteria
Strawberries, Raspberries or Black Berries
Peaches
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32.
Oranges and Lemons
Bananasand Mangoes
Dried Fruits
Fruit Juices
Nuts
Colours as a Source of Bacteria
Eggs as a Source of Bacteria
Destruction of Bacteria by Pasteurization
Recontamination of the Mix after Pasteurization
The Effect of Ageing on the Bacterial Count
The Effect of Freezing and Hardening on the Bacterial Count.
BACTERIOLOGICAL STANDARDS FOR ICE CREAM
Milk and Milk Products
Ice Cream Defined
Classification of Ice Creams and Related Frozen Foods
Composition of Commercial Ice Cream
The Ingredients Used in the Manufacture of Ice Cream
Quality of Dairy Products for Ice Cream
Sweeteners for Ice Cream
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33.
Ice-Cream Stabilizers
Flavouring Materials
Preparationof the Ice-Cream Mix
Technical Skill Necessary
Procedure in Calculating a Mix
Homogenizing the Mix
Agening the Mix
Quality of Ice Cream
Ice-Cream defects
Body and Texture Defects
Colour Defects
Distribution of Ice Cream
Ice-Cream Making in the Home
13. METHODS OF LABORATORY TESTS
JUDGING FLAVOUR AND AROMA
Gerber Test for Fat in Milk and Cream
SNF and Total Solids in Milk by Lactometer
Analysis of Fat in ice Cream
Ether Extraction Test
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34.
Preparation of Sample
Procedure
GerberTest
Apparatus and Reagents
PREPARATION OF SAMPLE
Procedure
Determination of Total Solids
Mojonnier Total Solids Test
Procedure
Apparatus and Reagents
Procedure
Calculation
MEASUREMENT OF VISCOSITY
Pipette Method
Borden Flow Meter Method
Brookfield Viscometer
Calculation
Test for Ammonia Leaks
Surface Tension
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35.
14. ICE CREAMNOVELTYIMPULSE PRODUCTS
MOLDED NOVELTIES
EXTRUDED NOVELTIES
15. ICE CREAM SHELF-LIFE
Temperature Fluctuations and Ice Recrystalliation
The Role of Stabilizers
Maintaining Shelf-Life
16. ICE CREAM INGREDIENTS
Milkfat (or "Butterfat") /FAT
Milk solids-Not-Fat
Lactose Crystallization
Sweeteners
Stabilizers
Locust Bean Gum
Emulsifiers
Polysorbate 80
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36.
17. MIX CALCULATIONSFOR ICE CREAM AND FROZEN DAIRY DESSERTS
Problem 1
Solution
Problem 2
Solution
Problem 3
Problem 4
Problem 5
Problem 6
Problem 7 (Using Liquid Sweeteners)
18. STRUCTURE OF ICE CREAM
Colloidal Aspects of Structure
Ice Cream Meltdown
Structure From The Ice Crystals
19. THEORETICAL ASPECTS OF THE PREEZING PROCESS
The Orocess of Crystallization
Importance of Crystallization Rate
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37.
Importance of TemperatureFluctuations and Re-Crystallization
Formation of The Glassy Phase in Frozen Foods
Formation of a Dilute Glass
20. ICE CREAM MANFACTURE
Blending
Pasteurization
Homogenization
Ageing
Freezing and Hardening
Hardening
21. ICE CREAM FLAVOURS
Introduction
Vanilla
Chocolater and Cocoa
Fruit Ice Cream
Nuts in Ice Cream
Colour in Ice Cream
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38.
22 HOMEMADE ICECREAM
Ingredients Used
Preparation of the Ice Cream Mix
Aging the Mix
Freezing the Mix
Regular Vanilla Ice Cream
Low Calorie Vanilla Ice Cream
Milk Substitute Vanilla Ice Cream
Hints for Making Good Ice Cream
23 ICE CREAM FORMULATIONS
ICE CREAM MIX GENERAL COMPOSITON
Formulation Considerations
Economy Brands
Standard Brands
Premium Brands
Super-premium Brands
Suggested Mixes
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39.
24. AUTOMATIC ICECREAM BAKIGN MACHINE AGC-SERIES
Features
ACG Series
Features
Gas Burners
Scraping Device
Cone Ejector
Stacking Device
Output Details
Baking Process
25. NEW PROCESSING TECHNOLOGY -NEW PREMIUM 3D ICE CREAM PRODUCTS
Enhanced Market Opportunities
Low Capital & Flexibility
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40.
26. SAMPLE ICECRDAM CONE DRAWING
Design for Cone Diameter 30-40 mm
Design for Cone Diameter 40-50 mm
Design for cone Diamaeter50-56 mm
Design for Sugar Conges
Design for Cups
DIRECTORY SECTION
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Niir Project ConsultancyServices (NPCS)
can provide Process Technology Book on
Flavoured Ice Cream
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