PROJECT ON

PROCESSING ON RAW MILK FROM FARM AND ITS QUALITY

CHECKING AND ASSURANCE

PRODUCTION OF ICE CREAM AND ITS QUALITY CHECK AND

ASSURANCE

Submitted to-
School Of Basic And Applied Science
SANSKRITI UNIVERSITY ,CHHATA(MATHURA)
UTTAR PRADESH

Place Of Training-
Mother Dairy Food Processing Ltd. Patparganj,New Delhi

Submitted by
DEEPTI KHANDELWAL
M.Sc (industrial chemistry)
Enrollment. No: 17001202006
IV Semester

1
ACKNOWLEDGEMENT
I feel pleasure in expressing my profound sense of gratitude and indebtedness to
mother dairy organization who has given me the authority to get training under
them.

I am highly obliged to Mr Ram Mohan Rao (Head of Mother Dairy )New Delhi
MrJanmejayaSamal (HR Manager) to arrange my training in their esteemed
organization.

I am grateful to Dr.Durgeshwadhwa(industrial chemistry in Sanskriti University)

for giving me permission letter to work in this organization.

I thanks all the workers in ICP Lab, BVM Lab, QA-QC Lab, DOCK Lab who really
showed cooperation and support.

I also thanks to my parents who has been the source of motivation, strength and
support which led me to attain success.

DEEPTI KHANDELWAL

2
 DECLARATION

I Deeptikhandelwal, hereby declare that my report on topic:

“Process of raw milk from farm and its quality check and assurance.”

“Processing and production of ice cream and its quality check and assurance.”

is a result of my own work and indebtedness to work publications.

Correction if any will duly acknowledged.

PLACE- Mother Dairy Food Processing Ltd, Patparganj, NewDelhi.

Date-

DEEPTI KHANDELWAL

3
 CERTIFICATE

This is to certify that Ms. Deeptikhandelwalenrollment number

1701202006has completed is internship at milk and ice cream division of
mother dairy fruit and vegetables Pvtltd.patparganj Delhi and has
submitted her project report ( January- February).

This report is the result of her own word and to the best of my
knowledge,no part of it has earlier comprised any other report,
dissertation or book. Thisproject was carried out under my overall
supervision.

Date- Authorised signature-

Place- BVM DEPARTMENT-

ICP DEPARTMENT-

QA/QC LAB-
4
 ACKNOWLEDGEMENT

I would like to express my special thanks to gratitude to my industrial

chemistry teacher “ miss Durgeshwadhwa” for their able guidance and
support in completing my project report.

I would also like to extend my gratitude to the HOD sir “ MrUmeshand

Dean sir Dr.Kalyanfor providing me with all the facility Dr.Gopalarora
that are required.

DATE-DEEPTIKHANDELWAL

5
CERTIFICATE

This is to certify that miss deeptikhandelwal a bonofiedstudent of a

SANSKRITI UNIVERSITY mathurapursuing her master in industrial
chemistry his worked on the project in Raw milk and quality check,ice
cream production and quality check from ( 15 January-16 February) and
has successfully completed the dissertation program.

Her conduct during the course was good.

6
TABLE OFCONTENT-

 Executive summary. 09
 Introduction of MOTHER DAIRY 10-12
1. History. 10
2. Mother dairy company. 11
3. Nutritions 12
 Mother Dairy Bulk Vending Milk Plant 13-21
1. Milk Sampling and Processing
o CLARIFICATION
o STANDARDIZATION
o HOMOGENIZATION
o PASTEIRIZATION
2. Chilling
3. Dispatch
4. Adulteration of milk and milk products
5. CIP system
6. List of quality test
7. Chemical Analysis
8. Microbiological Analysis
 Mother Dairy Ice Cream Plant. 21-36
1. Introduction
2. Role of different constituents
o Milk fat
o Milk solid not fat
o Stabilizer
o Emulsifier
3. Flow chart of manufacture
4. Considering individual step
7
5. CCPs in ICP

6. OPRP in ICP

7. Processing equipment

8. CIP of ICP

9. Quality test of ice cream.

 Reference. 36

8
Executive summary

The report consist of the details on mother dairy fruit and

vegetable Pvt ltd.Parpatganj Delhi. It is one of the most
effluent company of India for processed milk and milk
products. The main aim of it is the welfare of the society by
providing quality milk to it’s consumer at an affordable
price. This report also contains the detailed information
about the rise in population with respect to rise in dairy
Industry. The dairy Industry has being studies in detail, so
that can be converted into information which can be used by
mother dairy for strategizing it’s marketing advertisement
areas.

It has various function department such as the production,

human resources, finance marketing, purchase and stores,
quality assurance, dispatch and logistics.

This report will help mother dairy to make strategies for

their long term objective.

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INTRODUCTION

History
Mother Dairy was commissioned in 1974 as a wholly owned
subsidiary of the National Dairy Development Board {NDDB}. It
was an initiative under Operation Flood, a dairy development
program aimed at making India a milk sufficient nation. Mother
Dairy sources a significant part of its requirement of liquid milk
from dairy cooperatives and village level farmer centric
organizations.
The company originally focused on Delhi and other parts of
the National Capital Region (NCR). It later expanded to other
regions in India.

MOTHER DAIRY COMPANY :

“Mother Dairy” is the single largest brand of milk in India as well as in Asia,
marketing about 4.45 million litres of milk per day. Mother Dairy commands 62%
market share in the organized sector in and around Delhi, primarily because of
consistent quality and service- whatever be the crises- floods, transport and selling
around 8.5 lakh litres toned milk through Bulk Vending shops.

Mother Dairy, Delhi is an IS/ISO-9001:2000 and Hazard Analysis Critical

Control Point (HACCP) and IS-14001:1996 Environment Management System
(EMS) certified Organization.

Mother Dairy is the (HACCP) and IS-14001:1996 Environment Management

System (EMS) certified Organization.

Mother Dairy is the First Dairy in the country to implement ISO-14031

(Environment Performance Evaluation) project. The company Quality Assurance
Laboratory is ISO/ISE-17025:1999 certified by NABL (National Accreditation
Board for Testing a commission nd Calibration Laboratory) Development of
Science Technology, India. This provides assurance to the consumer in respect of
quality and safety of products manufactured and marketed by Mother Dairy.

10
Mother Dairy was commissioned in 1974 as a wholly owned subsidiary of the
National Dairy Development Board (NDDB). It was an initiative under Operation
Flood, the world's biggest dairy development program launched to make India a
milk sufficient nation. Over the years, Mother Dairy has contributed significantly in
achieving this objective through a series of innovations and programs. Today,
Mother Dairy manufactures markets & sells milk and milk products including
cultured products, ice creams, paneer and ghee under the Mother Dairy brand. The
Company also has a diversified portfolio with products in edible oils, fruits &
vegetables, frozen vegetables, pulses, processed food like fruit juices, jams, etc. to
meet the daily requirements of every household.

A significant portion of its income is ploughed back into the value chain to support
and maintain the system. Brand Mother Dairy sources a significant part of its
requirement of liquid milk from dairy cooperatives and village level farmer centric
organizations. The Company is committed to uphold institutional structures that
empower milk producers and farmers through processes that are equitable.A
significant portion of its income is ploughed back into the value chain to support
and maintain the system.

Safal, F&V arm of Mother Dairy was the first Company to organize the fruits and
vegetables business in India. Today Safal is the market leader in organized fruit &
vegetable retail business in Delhi NCR and operates the largest number of F&V
Stores in Delhi NCR and has significant presence in Bangalore. Safal was also the
first brand in India to launch frozen vegetable in mid 90s. Over the years, the brand
has gained significant customer support and has become a household brand with
market leadership and presence across the country.

Mother Dairy is also present into edible oils segment under the brand name Dhara
which was launched under the 'Operation Golden Flow' program of NDDB as a
market intervention program to address a larger cause of the Indian farmers &
consumers. Trust, Purity and Taste are the hallmarks of Dhara cooking oil.

It has been a constant endeavor at Mother Dairy to stay connected with its
stakeholders. The corporate tag line of the latest brand campaign - Happy Food
Happy People - captures the essence of what the Company stands for. Mother Dairy
is committed to bring happiness to every individual with its range offering pure,
hygienic and adulteration-free high-quality products which has been the strength,
differentiator and heritage of the brand over years.
11
  Nutrition Some simple guidelines for a healthy life:
Dairy
Dairy products are an excellent source of calcium. Calcium is important because it
builds strong bones to last a lifetime. Milk, Cheese and Yogurt are great sources of
calcium. Three servings should be included in your diet every day.

Fats
Limit the fats and oils you eat. your body needs some fat for energy and to keep you
warm, but too much fat can make you overweight and cause health problems when
you're older. A little bit of fat goes a long way.

Grains
Whole grains are an important source of fiber, which keeps your digestive system
working property. Included in this group are pasta, rice, and whole-grain breads and
cereals. Six servings of whole grains should be eaten every day.

Vegetables
Remember to eat your vegetables, especially those dark green and orange ones.
Vegetables are an important source of vitamins and minerals and are also a good
source of fiber. Eat at least three servings every day.

Fruits
Sweet, juicy fruits should definitely be part of the healthy diet. Fruits can add
important vitamins and fiber to your diet. you should eat at least two servings each
day.

Proteins
Meat, poultry, fish, dry beans, eggs, peanut butter and nuts are good sources of
proteins. These foods contain iron and other important nutrients your body needs to
build strong muscles. Eat at least two servings each day.

Water
Drinking water is one of the easiest and most important things we can do to keep
our bodies healthy. Drink at least six glasses of water every day.

Exercise
It is important to exercise to help your body burn the food it is taking in. The more
active you are, the better!
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 Mother Dairy Bulk Vending Milk Plant:-

Raw milk at Reception:-

Raw milk received through insulated road/rail tankers at a very low temperature thus
retaining the freshness of milk. The milk goes for more than 25 stringent quality tests
before it is accepted for the processing of milk.

Milk achieved from individual produces is checked for all the basic quality
parameters meeting the company specifications and required norms at respective
collection and chilling centres.

Milk processing (pasteurizer plant):-

Unprocessed milk may contain small dirt particles invisible to the naked eye. In order
to remove these particles the milk has to be processed.

In any kind of industry various processes are undertaken to process the raw materials
to obtain the final product. So each process can be divided into discrete steps which
13
when undertaken one by one lead to the complete process. In Mother Dairy, the
process is to process the raw milk in the required standard conditions to reach the
final processed milk at the desired standards.

Standards for the processed Toned milk are as follows:

Fat contents: 3.05%

Solid non-fat contents: 8.56%

Temperature: 2-4 degrees

Methyl blue re-colouration time (MBR): 5 hours minimum

Processing of milk is done in 4 steps:

1- CLARIFICATION
2- STANDARDIZATION
3- HOMOGENIZATION
4- PASTEURIZATION

CLARIFICATION:-
The chilled milk from silos goes to the clarifier after pre-heating. The clarifier spins
the milk at very high speed, removing all the dust particles that are invisible to naked
eye.
STANDARDIZATION:-
Milk from different breeds of cows and buffaloes may vary in its compositions,
before supply to the market, it is standardize by raising or lowering the Fat and SNF
percentage in the milk to a desired level, so as to deliver the milk to consumers as per
prescribed norms of FSSAI. The milk, which reaches the silos 1,2,3 contains mixed
raw milk and 4&5 contains skimmed milk comprises different proportion of Fat and
SNF. Now to obtain toned milk of 3% Fat and 8.5% SNF different proportion of milk
from different silos is calculated and processed and are directed to processed milk
silos.
HOMOGENIZATION:-
In this process milk is processed at a very high pressure during which the large fat
globules present in milk and milk become whiter and thicker. Milk become
homogenized for consumer who do not like cream layer on top. Homogenization
improves palatability of milk and is easily digestible.

14
EFFECT OF HOMOGENIZATION:-
The fat globules are surrounded by a membrane 5-10mm thick. The membrane has
properties of an emulsifier and keeps the emulsion, milk stable. During
homogenization the original membrane is destroyed and the first result is a rise in
interfacial tension soon falls again. The new emulsion therefore, remains stable even
after homogenization.
PASTEURIZATION:-
The milk is then pasteurized, named after Louis Pasteur, a French scientist who
invented the process to use in milk. Pasteurization was first applied by Dr. soxhiet of
Germany. This involves heating of milk to 72 degree to 75 degree Celsius for 15
seconds and then cooling it down to 4 degree Celsius. The process kills all
pathogenic bacteria present in the milk making. It makes milk sale for consumption.
Pasteurization, unlike boiling does not affect the nutritional value of milk.
CHILLING:-
Here milk is finally chilled to 4-50C using chilled water which are being pumped
from ice silos. The chilled water temperature ranges from 1.5-30C and chilled milk
temperature from 4-60C. If the chilled milk temperature exceeds 90C the milk will be
again circulated through the systems so a temperature transmitter continuously
displays the temperature on monitor so that continues monitoring can be done and if
temperature rises continuously the refrigeration section take necessary action in this
regard so as to reduce temperature. After chilling milk is pumped into silos.

VITAMIN A & D ADDITION:-

Toned milk during processing is fortified with vitamin A addition is done using
vitamin A acetate. Vitamin acetate is added in the balance tank for each shift. The
amount added is 180ml of vitamin A acetate in one lakh litres of milk so that the milk
contains 2000IU of vitamin A.

DISPATCH:-
After the Fat and SNF quality testing of PM silo is done and quality is full, the silo is
marked for dispatch before dispatch milk is pumped over to glycol chillers and the
milk is chilled to 20C in glycol chillers. Here instead of chilled water, chilled glycol
of approximately -0.50C is passed into the chillers. The chilled milk is then filled into
the tankers and the tankers then go to the milk vending outlets.

15
ADULTERATION OF MILK AND MILK PRODUCT
Adulteration
Dairy adulteration is an act of intentionally degrading the quality of dairy offered for
sale either by the admixture or substitution of inferior substance or by the removal of
some valuable ingredient. Dairy adulteration takes into account not only the
intentional addition or substitution or abstraction of of substance which adversely
affect nature, substance and quality of dairies, but also their incidental contamination
during the period growth, harvesting, storage, processing, transport extraneous
matter.

“Adulterant” means any material which is or could be employed for making the dairy
unsafe or sub-standard or misbranded or containing extraneous matter.
Dairy is adulterated if it’s quality is lowered or affected by the addition of substances
which are injurious to health or by removal of substances which are nutritious.

Dairy is declared adulterated if:

1. A substance is added which depreciates or injuriously affects it.
2. Cheaper substances or inferior substances are substituted wholly or in part.
3. It is imitation
4. It is colored or otherwise treated, to improve its appearance or if it contains
any added substance injurious to health.
5. For whatever reason its quality is below its standard.

CIP SYSTEM
Cleaning In place also called In-place cleaning refers to that system of cleaning
which does not require the daily dismantling of dairy equipment. Containers and
machines working on milk are subjected to the gradual growth of bacteria with the
passage of time. So in order to ensure the proper processing of milk and no bacteria
passes to the processed milk the milk containers i.e. silos and the plant have to be
cleaned after eight hours. So in order to ensure proper cleaning a proper CIP plant is
required in which cleaning in place is done. Further the CIP process is dependent on
the type of the machine/container and there are only slight variations to the general
procedure.

The cleaning process in general has following steps:

 Lye (NaOH) 70 to 750C
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 Acid (Nitric acid) 70 to 750C
 Hot water 80 to 900C
 Soft water 37.40C

Process of CIP:

Recovery of product residues by scraping, drainage and expulsion with water or

compressed air
Pre-rinsing with water to remove loose dirt
Cleaning with detergent
Rinsing with clean water
Disinfection by heating or with chemical agents (optional); if this step is included, the
cycle ends with a final rinse, if the water quality is good.
Step1- circulation of cold water (soft)
Step2- circulation of lye solution, 30 min
Step3- circulation of hot water, 10 min
Step4- circulation of acid solution, 20 min
Step5- circulation of cold water.

17
List of Quality tests:
1. Seal & check for cleanliness
2. Presence of foreign matter
3. Temperature
4. Organoleptic Evaluation
5. Clot of Boiling (COB)
6. Alcohol test
7. Neutralizer test
8. Acidity test
9. Ammonium compound test
10.M.B.R.T test
11.Urea test
12.Starch and cereal test
13.Salt test
14.Glucose test
15.Sugar test
16.Maltodextrin (enzymatic) test
17.Detergent test
18.Formalin test
19. Hydrogen peroxide test (H 2O2)
20.Sodium ions PPM test
21.R.M. Value (Reichert Missal)
22.B.R. Value (Butyrometer Refractometer)
23.Fat test
24.Protein test
25.S.N.F. test

DETECTION METHOD
Seal and check for cleanliness
1. Presence of foreign matter: Take out 10 to 15 lit of milk in a bucket through
a small hosepipe or directly from the tanker valve. Filter this milk through a
small plastic sieve provided for the purpose. Check for presence of foreign
matter in the milk. If milk contains some undesirable matter, drain out some
more milk and check again. If foreign matter is found, reject the tanker. If no
foreign matter is found climb on the tanker , check the hygienic condition.
18
2. Temperature: checked by using thermometer.
3. Organoleptic Evaluation: check taste & flavour of milk
4. Clot of Boiling test: conduct COB test by taking 2ml of milk in a test tube,
boil on the flame of spirit lamp. Formation of clots in the test tube indicates
COB positive test and milk is unacceptable
5. Alcohol test: take 2ml of milk in a test tube add 5 ml alcohol with constant
shake, formation of precipitates indicates alcohol test positive and such milk
is unacceptable.
6. Acidity Test-Taking 10ml milk and 10ml distilled water in 100 ml conical
flask; titrate against N/10 NaoH using phenopthelein as indicator to check
acidity.Acidity above 0.153%is not acceptable or use acidometer for titratable
acidity.
7. Urea Test-Take 2ml milk in test tube, add 2ml DMAB solution and mix the
contents. Appearance of yellow color indicates the presence of urea and the
milk is unacceptable.
8. Starch Test-Take 3ml milk in test tube,boil and cool under tap water add 2
drops of 1% iodine solurion. Appearance of blue color indicates the presence
of starch.
9. Sugar Test-Take 3ml of Milk in test tube and add 5ml dilute HCL containing
resorcinol (0.1gm resorcinol dissolved in 100ml dilute HCL). Mix well and
keep the test tube in boiling water for 5min.Brick red color formation
indicates sugar is positive.
10. Salt test-Take 2ml milk in test tube, add 5 ml silver nitrate (AgNO 3) and add

2 drops of potassium chromate indicates maroon color is acceptable

otherwise unacceptable.
11. Detergent Test-Take 1 ml milk in test tube, add 1 ml of MBR dye mixed

well and add 2 ml of chloroform followed by vortex for 15 seconds.

Centrifuge the contents 1500 rpm for 5 min. observe the layers after
centrifugation. Dark blue color in lower ring then rejected, light blue color
ring on lower ring so accepted.
12. Formalin Test-Take 2 ml of sample in test tube and add 2 ml of 90%

sulphuric acid( H2SO4) containing ferric chloride (5gm in 100 ml H 2SO4)

19
 from the side of the test tube slowly. Formation of purple ring at the junction
indicates formaldehyde is present in milk.
13. Hydrogen Peroxide Test-Take 5 ml milk in test tube and then add 5 drops of

venadium pentaoxide and shake it well. Change the color of milk to blue then
it is positive.
14. Sodium ion PPM Test-Detection of sodium content of milk, 25 ml of sample

in 50 ml of beaker with 2.5 ml of ISA and take reading. Final reading will be
displayed in PPM. Please do not switch off the instrument as it will required
calibration after power on.
15. R.M. value (Reichert Missel) Test-Milk is collected in then milk is

converted into ghee. Take 5 ml of ghee in R.M. flask, add 200 gm glycerol,
add 2 ml sodium hydroxide(NaOH) after that the saponify of flame by using
glass beads. After then add 90 ml distilled water and 50 ml sulphuric
acid(1N) then stand by for heating. After 20 min. separate the R.M. flask and
keep for cooling and filter by using filter paper. After filter take 100 ml
solution 250 ml conical flask, add 1 ml phenolphthalein and titrate with N/10
NaOH change the color to pink.
16. B.R Value (Butyrometer Refractometer) Test-One drop of ghee put on

refractometer at temperature 400C and take a reading.

17. Fat Test-Take10ml of milk in Butyrometer, add 1ml amyl alcohol and add

distilled water for the level maintaining and tightly pack with stopper. Mix
well and keep in Gerber centrifuge for 1500rpm for 5min.
18. Maltodextrin (Enzymatic) Test-Take 10ml milk in 100ml beaker and add

1ml enzyme mix properly and keep in water bath for 30min.After 30min
check pH by using pH strstrip

Mother dairy ice cream plant :-

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Introduction:-Ice cream is a frozen dairy product made by suitable bending
and processing of cream and other milk products,together with sugar and
flavour,with or without stabilizer or colour and with the incorporation of air during
the freezing process.

According to the FSSAI(2006), icecream, kulfi, chocolate icecream or the softy

icecream (hereafter referred to as the said product)means the product obtained by
freezing a pasteurized mix prepared from milk and or other products derived from
milk with or without the addition of nutritive sweeting agents, fruit and fruit
products, egg, and egg products, coffee, cocoa, chocolate, condiments, spices,
ginger and nuts and it may also contain bakery products such as cake or cookies as
a separate layer and/or coating. The said product may be frozen hard or frozen to a
soft consistency; the said product shall have pleasant taste and smell free from off
flavour and rancidity; the said product may contain food additives permitted in
these regulation including appendix A; the said product shall confirm to the
microbial requirements specified in Appendix B; the said product shall confirm to
the following requirements namely:-

Medium Fat Ice

Requirements Ice Cream
Cream
Low Fat Ice Cream

Total Solid Not less than 36.0% Not less than 30% Not less than 26%

Wt /Vol(Gms/L) Not less than 525 Not less than475 Not less than 475
More than 2.5%but
Milk Fat Not less than 10.0% Not more than 2.5%
less than 10.0%
Milk Protein
Not less than 3.5% Not less than 3.5% Not less than 3.0%
(Nx6.38)

Table:-FSSAI Guidelines for ice cream.

Role of different constituent in Ice Cream:-

Ice cream have the following composition:

 Greater than 10%milk fat by legal definition, and usually between 10%and as
high as 16%fat in some premium ice creams.

21
  9 to 12% milk-solid-not fat(MSNF) :this component also known as the serum
solid contains the protein (caseins and whey proteins) and carbohydrates
(lactose) found in milk.
 12 to 16 % sweetener;usually a combination of sucrose and glucose based
corn syrup sweeteners.
 0.2 to0.5% stabilizer and emulsifiers.
 55 to 65% water which comes from the milk or other ingredients.

These percentages are by weight, either in the mix or in the frozen ice cream.
However, that when frozen, about one half of the volume of the icecream is
air(overrun:- Ice cream contains a considerable quantity of air, up to half of its
volume. This give the product its characteristics, lightness. Without air, icecrean
would be similar to a frozen icecube. The air contains is termed its overrun, which
cab be calculated mathematically), so by the volume icecream, these numbers can
be reduced by approximately one-half, depending on the actual air content.

Milk fat (or Butter):- Milk fat or fat in general, including that from the non dairy
source is important to icecream fot the following reason:

 Increase the richness of flavour in icecream(milk fat more so than non-dairy

fats)
 Produces a characteristic smooth texture by lubricating the palate.
 Helps to give the body to the icecream, due to its role in fat destabilization.
 Aids in good melting properties, also due to its role in fat destabilization.
 Aids in lubricating the freezer barrel during manufacture (Non-fat mixes are
extremely hard on the freezing equipment).

The limitation of the excessive use of butter fat in a mix include :

 Cost
 Hindered whipping ability
 High caloric value

The best source of butter fat in ice cream for high quality flavor and convenicence
is the fresh sweet cream from fresh sweet milk. Other sources includes butter or
anhydrous mill fat. During freezing of ice cream, the fat emulsion which exist in
the mix will partially destabilize or churn as a result of the air incorporation, ice
crystallization and high shear force of the blades. This partial churning is
necessary to setup the structure and texture of the ice cream, which is very similar
to the structure in whipped cream.

22
Milk Solid Not Fat(MSNF):- The serum solids or the milk solid not
fat(MSNF)contains the lactose, caseins, whey proteins, and minirals(ash content)of
the product from which they were derived. They are an important ingredient for the
following beneficial reasons:

 Improve the texture of ice cream, due to the protein functionality.

 Help to give body and chew resistance to the finished product.
 They are capable of allowing a higher overrun without the characteristic snowy
or flaky texture associated with high overrun, due also the protein functionality.
 May be a cheap source of total solids, especially whey powder.

The limitation on their use include off flavour which may arise from some of the
products and an excess of lactose which can lead to the defect of sandiness
prevalent when the lactose crystallizer out of solution. Excessive concentration of
lactose in the serum phase may also lower the freezing point of the finished product
to an unacceptable level.

Sweetner:- A sweet ice cream is usually desired by the consumer. As a result,

sweetening agents are added to ice cream mix at a rate of usually 12-16% by
weight. Sweeteners improves the texture and palatability of the ice cream, enhance
flavours, and are usually the cheapest source of total solids. In addition, the sugars,
including the lactose from the milk component, contribute to a depressed freezing
point so that the ice cream has some unfrozen water associated with it at very low
temperatures typical of their serving temperatures -15o to -18oC. Without this
unfrozen water, the ice cream would be too hard to scoop.

A balance is involve between sweetener,total solid, and freezing point.

Stabilizers:- the stabilizer are a group of compounds usually polysaccharides food

gums, that are responsible for adding the viscosity to the mix and the unfrozen
phase of the ice cream. These results in many functional benefits, listed below, and
also extent the shelf life by limiting ice recrystallization during storage. Without the
stabilizer, the icecream would become coarse and ice very quickly due to the
migration of free water and the growth of existing ice crystals.

The functions of the stabilizers in the ice cream are:

 In the mix:- to stabilizr the emulsion to prevent creaming of fat, and in the
case of carrageenan, to prevent serum separation due to incompatibility of the
other polysaccharides with milk protein, also to aid in suspension of liquid
flavour.

23
  In the ice cream at draw from the scraped surface freezer:-To stabilize
the air bubbles are to hold the flavouring, e.g.-ripple sauce , in dispersion.
 In ice cream during storage:-To prevent lactose crystal growth and retard or
reduce ice crystal growth during storage, also to prevent shrinkage from
collapse of the air bubble and to prevent moisture migration into the
package(in the case of paperboard) and sublimation from the surface.
 In the ice cream at the time if consumption:- To provide some body and
mouthfeel without being gummy, and to promote good flavour release.

Emulsifier:- The emulsifier are a group of compound in ice cream that aid in
developing the appropriate fat structure and air distribution necessary for the
smooth eating and good meltdown characterstics desired in the ice cream. Since
each molecule of an emulsifier contains a hydrophilic portion and a hydrophobic
portion, they resides at the interface between fat and water. As a result they act to
reduce the interfacial tension or the force which exist between the two phase of the
emulsion. This causes a desorption of protein from the fat droplet surface,which
promotes a destabilization of the fat emulsion (due to a weaker membrane)leading
to a smooth, dry product with good meldown properties.

FLOW CHART OF MANUFACTURE:-

Selection of ingredients

Mixing of ingredients
(Toned Milk, SMP/WMP at 35degree celsius,
WPC, sugar+ stabilizer at 60 degree celsius)

Figuring the mix

(Table butter and remaining sugar at 65 degree celsius)

Holding the mix for around 30 minutes

24
 Mix transfer pump

Passing through magnetic filter (1000 Gauss)

Passing through duplex filter (100 mesh size)

Homogenization of mix (60-65 degree celsius)

1500 psi and 500 psi

Pasteurization
(Inlet temp. 65- 70 degree celsius)
(Outlet temp. 83- 87 degree celsius)

Holding tube (25 sec)

FDV
(If pasteurization is at lower temp. then mix is sent back in mixing vat)

Chiller
(Inlet temp. 83-87 degree celsius)
(Outlet temp. < 9 degree celsius)

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 Ageing
4-5 degree celsius for 4 to 6 hrs. (min.)
2-3 days (max.)

Flavor tank

Continuous Freezer (-4 to -5 degree celsius)

Packaging

Passing through metal detector

Cold storage (>-20 degree celsius)

Considering individual process step:-
Making the mix:

In order to make good ice cream, the milk products and other ingredients must first
selected and combined so as to produce the desired body and delicately blend
flavor. The selection of good ingredients and calculation of a satisfactory
composition proceed the mixing of the ingredients in a vat, where they can be
heated to facilitate dissolving, blending and pasteurizing.

The order in which ingredients are added as follows:

 Liquid ingredients, basically milk, are paced in the jacketed vat provided
with a power stirrer and the agitation and heating started at once.
o
 Powder is added at 35 C
 Sugar, emulsifier and stabilizer us added while the liquid material as agitate.
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  Butter is added at about 60o C.
 The mix is agitated and heated to 65-70o C and then pumped to duplex filter.
 Before reaching to the transfer pump mix is passed through magnetic filter of
10000 gauss to check and prevent the dust or the metallic particals in the mix.

Filtration:

The mix is then filtered using a duplex filter, where it passed through a pore size of
100 mesh size filter, in order to make a mix completely free of extraneous matter
and give the mix a smooth consistency.

Homogenization:

Homogenization of the ice cream mix is essential. The main function of the
homogenization is to make a permanent and uniform suspension of fat by reducing
the fat globule to a very small diameter, preferably not more than 2 microns.

Here a pressure of 1500 psi at first stage and 500 psi at second stage is applied.

Advantages:

 Reduces the size of th fat globules.

 Improves whipping ability.
 It prevents fat separation during ageing.
 Produces more uniform ice cream with a smother texture.
 Decrease the risk of churning occurring in the freezer.
 Leads to the use of slightly less stabilizer.

Pasteurization:

It accomplished in two step:

Heating:- It is compulsory for all ice cream mixes to destroy all pathogenic or
disease-producing bacteria, thereby safeguarding the health of the consumer.
Pasteurization has come to be considered as highly desirable and requires only
slight additional expense, since the homogenization process can be accomplished
at the pasteurization temperature level.

The pasteurization time temperature combination in the ice cream plant here is 83-
87o celsius for 25 seconds.

Advantages:
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  It improves keeping quality.
 It renders the mix completely free of pathogenic bacteria.
 It improves flavor.
 It dissolves and helps to blend the ingredients of the mix.

Chilling:- The mixed is then chilled to about 7 degree celsius to facilitate ageing
which it is pumped over to ageing vat.

Ageing the mix:

The mix is then aged for four hours at 7 o c. this allows time for the fat to cool down
and crystalize, and for the protein and polysaccharide to fully hydrate. Aging
provides the following functions:-

 Improves whipping qualities of the mix and body and the texture of the
ice cream.

It does so by:

 Providing time for fat crystallization, so the fat can partially coalesce.
 Allowing time for full protein and stabilizer hydration and a resulting slight
viscosity increase.
 Allowing time for membrane rearrangement and protein/emulsifier
interaction, as emulsifier displace protein from the fat globule surface, which
allows for a reduction in stabilization of the fat globules and enhanced partial
coalescence. Aging is performed in insulated or refrigerated storage tanks,
silos,etc. time temperature combination is used for the ageing of the mix in
the Mother dairy is 7o C for 4 hours, for quality assurance of the mix , it is
tested for quality and legal standards, after assuring it is passed for further
processing.

Flavour addition: The mix is drawn into flavor tank where liquid flavor, fruit
purees or colour are added.

Freezing: The mix then enters the dynamic freezing process which both freezes a
portion of the water and whips air into the frozen mix. The ‘barrel’ freezers is a
scraped-surface, tubular heat exchange, which is jacketed with a boiling refrigerant
such as ammonia or frozen. Mix is pumped through this freezer and is drawn off
the outer end in a matter of 30 seconds, (or 10 to 15 minutes in the case of batch
freezer) with about 50% of its water frozen. There are rotating blades inside the
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barrel that keep the ice sharped off the surface of the freezer and also dashers inside
the machine which help to whip the mix and incorporate air. As the ice cream is
drawn with about half if its water frozen, particulate matter such as fruits, nuts,
candy, cookies, or whatever you like, is added to the semi-frozen slurry which has a
consistency similar to soft-serve ice cream. In fact, almost the only thing which
differentiates hard frozen ice cream from soft-serve, is the fact that soft serve is
drawn into cones at this point in the process rather than into packages for
subsequent hardening.

Hardening:- hardening is a process step which is performed only for stickless

candies, bars and frozen candies. During hardening, ice cream are passed though a
hardening chamber(blast freezer) in which the ice cream are rotated at around -40 o
C for desired time depending on the speed of conveyor. Due to air convection, ice
cream are chilled and hardened during this process step. Below about -25 o C, ice
cream. The factors affecting hardening are those affecting this rate of heat transfer:

 Temperature of blast freezer- the colder the temperature, the faster the
hardening, the smoother the product.
 Rapid circulation of air- increases convection heat transfer.
 Temperature of ice cream when placed in the hardening freezer- the colder
the ice cream at draw, the faster the hardening – must get through packaging
fast.

Packing :- ice cream are then packed after hardening. Packing takes place in two
phase for impulse and novelty products; primary and secondary packaging.

 Primary packing material used can be metallic laminates,plastic and

paperboards and are passed through the primary metal detector.
 Secondary packaging material primarily used is cardboard.

Storage:- ice cream are then passed through secondary metal detector and then
stored in cold store at temperature below -25o C.

CCPs in ICP
 PASTURIZATION
 METAL DETECTOR
 COLD STORE TEMPERATURE

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Other Pre Requisite Programmers In Icecream Plant:-
OPRP 1: CIP- Cleaning In Place:

OPRP 2: Duplex Filter-

OPRP 3: Air-

Processing Equipments:

1) Mix vat tank

2) Duplex Filter
3) Homogenizer
4) Pasteurizer
5) Chiller
6) Ageing tank
7) Freezer
8) Metal Detector
9) Fruit Feeder
10) Flavor Tank
11) Cup Machine
12) Matka Kulfi Machine
13) Blast Room
14) OPRP (1-CIP, 2-Filter, 3-Air)
15) CCP (1-Pasteurization, 2-Metal Detector, 3-Cold Store)
CIP of ice cream plant:-
Four factors which affect the CIP are:

I. Time:- the longer the detergent contact period, the higher the cleaning
efficiency. After some time, detergent eventually dissolve the hard
stains/soils from the dirty surface.
II. Temperature:- Elevating the temperature of a cleaning solution invreases its
dirt removal efficiency. Molecules with high kinetic energy dislodge dirt
faster than slow moving molecules of a cold solution.
III. Turbulence:- the turbulence create an abrasive force that dislodges stubborn
soil from the dirty surface.

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 IV. Titre:titre value indicates the strength of the cleaning solution. A
concentrated cleaning solution will clean a dirty surface much better than a
dilute one due to the increased surface binding capacity.

CIP solutions used are:

Lye solution:- Concentration - 1-1.5% Temperature- 65-70o C.

Lye solution is use to saponify fat in line.

Acid solution:- Nitric acid is used for CIP, generally at a lower concentration and
temperature than that of lye solution due to its corrosive nature. It is circulated at
60o C in lines.

For CIP solution the electrical conductivity of solution is set. For 1% solution it is
47 milli siemens. There are conductivity meter which are connected. If the
conductivity is less than concentration acid or lye added in the acid and lye tanks
untill the conductivity is met. For CIP cleaning first circuit is selected and then
objects and accordingly acid and lye programe are used.

Quality Test for Ice-Cream

1) Total solid
2) Fat Test
3) Acidity test
4) Protein test
1.Total Solid:-
Empty Dish weight
(It should be cool and moisture free)

2 gm ice-cream weight
(with pipette)

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 Spread in dish

Put on plate at 120 degree celsius

Keep in hot air oven at 102 degree celsius weight

2. Fat test:-
Take a cylinder put on weighing balance

Take 10 ml sulfuric acid in butyrometer

5 gm of ice-cream weighed

1 ml Amyl Alcohol

Distilled water
(For maintaining level) and shake after stopper

Centrifuge for 5 min

Reading observed

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3. Acidity Test:-
Take conical Flask

10 gm Sample

Add 40 ml distilled water

Add 1 ml phenopthelein

Titrate N/10 NaOH

(Light Pink)

Reading
4. Protein Test:-
Take conical Flask

10 ml ice-cream sample

Add 40 ml distilled water

Add phenolpthelein indicator

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 Add 0.4 ml Potassium Oxalate

Hold for 3 min

Mixing by Stirrer

Add 2 ml Neutralizer Formaldehyde

Again Titrate with N/10 NaOH

(Light Pink)

Reading

REFRENCES:-
1. www.motherdairy.com
2. www.dairymaharashtra.gov.in
3. Tests in manuals
4. www.indianjournal.com
5. www.scientificamerican.com

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