4/9/18

ICE CREAM
Daniel Paul P

Ice Cream

¨ Ice Cream – is a sweetened product containing milkfat, milk

solids-not-fat (MSNF), and other additives, and is frozen while
being whipped in a scraped surface freezer, and subsequently
consumed in the frozen state
¨ Composition / Main Ingredients:
¤ Milkfat
¤ Milk solids-not-fat
¤ Sweeteners and Flavor
¤ Stabilizers and Emulsifiers
¤ Water

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General Composition of Ice Cream

Component Concentration Function
Milkfat 10–16% • Indicator of perceived quality and/or value of the
ice cream
• Increases the richness of flavor of the ice cream
• Produces a characteristic smooth texture by
lubricating the palate
• Give body and desirable melting properties
• Considerable quantity of the fat must be
crystallized while whipping and freezing
Milk SNF 9–12% • Essential for their functional contributions of
lactose, caseins,
emulsification, aeration, and water-holding
whey proteins,
minerals (ash), capacity / viscosity enhancement
vitamins, acids, • Excess of lactose leads to lactose crystallization
enzymes (textural defect) – So, limit lactose content

Component Concentration Function

Sweeteners Sucrose: 10–14% • Improve the texture and palatability of ice
Sucrose
Corn Syrup: 3–5% cream and enhance flavors
Corn syrup solids
• Their ability to lower the freezing point of a
solution imparts a measure of control over
hardness
Stabilizers 0–0.25% • A group of hydrocolloid ingredients that are
Guar, locust bean gum
large molecules (macromolecules) and are
(carob), carrageenan,
sodium alginate, capable of interacting with water
xanthan, gelatin • By interacting with water these compounds
interact with proteins and lipids in the mix
• Produces smoothness in body and texture
and retard or reduce the growth of ice and
lactose crystals during storage – increases
shelf life

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General Composition of Ice Cream

Component Concentration Function
Stabilizers 0–0.25% • Increase the shelf life of ice cream.
Guar, locust bean gum
• Increase the viscosity of the mix,
(carob), carrageenan,
sodium alginate, • Aid in suspension of flavoring particles in
xanthan, gelatin the semi-frozen ice cream
• Slow down moisture and air migration from
the frozen product to the package – prevent
shrinkage of the product volume during
storage
• Prevent serum separation in the mix

Component Concentration Function

Emulsifiers 0–0.25% • Small-molecule surfactants (emulsifiers)
Mono- and di-glycerides,
that lowers the fat/water interfacial
Polysorbate 80, Egg
products tension in the mix – facilitates the
suspension of fat in water
• These molecules have • Produce a smoother body and texture in
two domains, one that the finished product – by enhancing
likes water partial coalescence of fat globule while
(hydrophilic) and whipping and freezing
another that likes fat • Improves aeration properties of mix
(hydrophobic) • Imparts good shape-retention properties
(referred to as “dryness”) to facilitate
molding, fancy extrusion, and novelty
product manufacture
Water 55–64%

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Quality and Safety of Frozen Dairy Products 467

the aeration properties of the mix; to produce an ice cream at extrusion with good shape-retention
properties (referred to as “dryness”) to facilitate molding, fancy extrusion, and novelty product
manufacture; to produce a smoother body and texture in the finished product; and to produce a
product with good shape-retention properties during melting [9,13,14]. Their mechanism of action
Sources
can be summarized as follows: of the
they lower Major interfacial
the fat/water Components tension in the mix, resulting in
protein displacement from the fat globule surface, which in turn reduces the stability of the fat globule
to partial coalescenceComponent Ingredients
that occurs during the whipping to Supply
and freezing process, leading to the formation
(but also supplies)
of an aggregated fat structure in the frozen product which contributes greatly to texture and melt-down
properties [9,13,14]. Their
Milkfatinteraction with proteins
Creamand role water)
(msnf, in structure formation will be described
in Section “Structural Changes Occurring during Freezing.”
Butter Emulsifiers
(msnf, water) or AMF used in ice cream manu-
facture are of two main
Milktypes: mono- and di-glycerides
solids-not-fat and sorbitan
Skim powder (water) esters. Of the latter, polysorbate
80 is a very strong promoter of fat destabilization in ice cream
Condensed [9] and is used in many commercial
skim (water)
stabilizer/emulsifier blends. Condensed milk (water, fat)
Sweetened condensed (water, sugar)
Whey powder (water)
PROCESSING
Sweeteners Sucrose
Mix Manufacture Corn syrup solids
Ice cream processing operations can be divided into Liquid
twosugars (water)
distinct stages: mix manufacture and freezing
operations (Figure 19.2). The manufacture
Stabilizers / Emulsifiersof ice cream
Added mix involves
as Stabilizers the following unit operations:
/ Emulsifiers
combination and blending
Water of ingredients, batchSkimor continuous
milk (msnf) pasteurization, homogenization, and
aging [9]. Ingredients are chosen to supply the Milk desired
(fat,components,
msnf) for example, cream or butter to
supply fat, on the basis of availability, ease of handling,
Water desired quality and cost. An algebraic solution
of the formulation is required, since many of the ingredients supply more than one component [9,11].
Pasteurization is designed to kill pathogenic bacteria. In addition, it serves a useful role in reducing
the total bacterial load and in solubilization of some of the components (proteins and stabilizers). Both
batch (>~69°C for ~30 min) and continuous (high temperature–short time: >~80°C for ~15–25 s)
systems are in common use. Provided that mix has been properly pasteurized and no post-pasteurization

Formulation Manufacturing
-Fat, 10%–16% -Sweetener, 14%–16% -Emulsifier, 0.1%–0.2%
-Milk SNF, 9%–12% -Stabilizer, 0.1%–0.2% -Water, 60%–64%

Batch pasteurization Homogenization Cooling

Blending

Continuous pasteurization/homogenization/cooling
Liquid Dry
ingredients ingredients Air
incorporation

Continuous freezing

Packaging Aging

Batch freezing/whipping

Particulate Flavor/color
addition addition

Hardening Storage/distribution

FIGURE 19.2 Processing flow chart for the manufacture of ice cream.

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Manufacturing

¨ Manufacturing Process is divided into two stages:

1) Ice cream Mix manufacture

¤ Combination and blending of ingredients

¤ Batch or continuous pasteurization

¤ Homogenization

¤ Mix Aging

2) Freezing operations

Manufacturing

¨ Mix Calculation: Mix formula is converted into recipe

¨ Formula – specify composition of the desired mix in

percentages
¨ Recipe – calculated weight and/or volumes of
ingredients needed to meet the formula requirements

¨ These calculations are called mix calculations

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Ice Cream and Frozen Desserts

Desired Mix Ingredients on Hand
Formula
of each component in each ingredient are laid o
13% Fat Cream (40% Fat)
table and summed. The total mass of each com
11% MSNF Skim milk
Skim milk powder (97% MSNF)
divided by the total mass of mix should yield the
15% Sucrose Sugar percentage.
0.5% Stabilizers Stabilizer
0.15% Emulsifiers Emulsifier Mix Calculation
Proof:
100 kg Mix
Ingredients Kilograms Kgs. Fat Kgs. msnf
Cream 32.50 13.0 1.75
Skim milk 46.65 — 4.20
EXAMPLE Skim powder 5.20 — 5.05
Sucrose 15.00 — —
Stabilizer 0.50 — —
Emulsifier 0.15 — —
Totals 100.0 13.0 11.0

Derivation of the Serum Point equations:

Problem 1 is resolved again using simultaneous eq
in a general way to show where the serum point eq
come from.
Manufacturing
On hand: cream @ 40% fat
(supplies fat, water, an
¨ Blending: at refrigeration temperatures 4°C or at warmer therefore can be thoug
a mixture of fat and ski
temperatures 45°C skim milk @ 9% msnf
(supplies water and ms
¨ Cold temperature – cream, liquid milk, and condensed skim
skim milk powder @ 97% msnf
are the ingredients (supplies water and ms
sucrose
¨ Warmer temperature – butter, butteroil/anhydrous milk fat
stabilizer
in combination with non-fat dry milk emulsifier

¨ Mixing tanks – usually conical bottom tank with agitator

Solution
- Only one source of fat, sucrose, stabilizer, and em

kg fat ! 100 kg mix " 13 kg fat/100 kg m

! 13 kg fat

(The explanation for this assumption becomes clea

moment!) 6

kg sucrose ! 100 kg mix " 15 kg sucrose/100

! 15 kg sucrose
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Mixing Tank – Example

1.Mixing tank
with heating/cooling jacket
2.Agitator
3.Thermometer
4.Emptying pump
5.Flow meter

Not for Examination – Only for Understanding

Manufacturing

¨ Pasteurization – destruction of pathogenic bacteria

¤ Batch Process – 69°C and for 30 min (steam jacketed vat)

¤ Continuous Process – 80°C for 25 sec (HTST heat

exchanger)

¨ Homogenization – for formation of fat emulsion

¤ Forcing the hot mix through a small orifice under pressures
of 15.5 to 18.9 MPa, depending on the mix composition.

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Manufacturing

¨ Aging – Maintain the mix at 4°C or lower without

freezing for four hours or more to enable
¤ Hydration of milk proteins and stabilizers (viscosity
increases)
¤ Crystallization of the fat globules, and a membrane
rearrangement (smoother texture & better quality product)

¨ Equipment – Insulated or refrigerated storage tank or silo

Freezing

¨ Freezing of ice cream mix has two distinctive stages:

1) Dynamic Freezing – Continuous Freezing in scraped-
surface heat exchanger under high shear and
incorporating air (over run)

2) Static Freezing – Rapid freezing of packaged ice cream to

maintain the small ice crystal sizes (Hardening)

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Freezing

¨ First stage of freezing: – Freezing & Overrun

¤ Continuous Freezing– whipping and freezing at the same time

¤ Incorporation of air into ice cream, termed overrun, is done to

produce desirable body and texture (increase volume)
¤ Freezing to ‘–6°C’ for large number of small ice crystals
formation & destabilization and coalescence of the fat

¤ Ice cream exits the freezer as a partially frozen slush

Vol. of ice cream produced − Vol. of mix used
% overrun =
Vol. of mix used

Ice Cream and Frozen Desserts 154-29

Not for Examination – Only for Understanding

Ice cream (×1000)
Ice cream mix
(×10,000) Mixed membrane 3-D fat
network
of protein and Air
emulsifier

Ice

Casein
micelles
Solution of
Partially-crystalline dissolved solutes
fat emulsion
Freeze-concentrated
unfrozen phase

FIGURE 154.17 A schematic representation of the structure of ice cream mix and of ice cream.
Ice Cream mix – Simple emulsion
Dispersed phase – Partially crystalline fat globules surrounded by interfacial
formed fat globule is practically devoid of any membra- destabilization. This is due to the fact that the protein mole-
nous materiallayer
and readily adsorbs
of proteins amphiphilic
and molecules
surfactants cules, and particularly the caseins, are considerably larger
from solution (93). The immediate environment supplies than the emulsifier molecules, such that a membrane made
the surfactantContinuous Phaseinclude
molecules, which – Serum phaseundena-
caseins, of the unadsorbed
up entirelycasein micelles
of emulsifier in thin (Figure 154.18). This
is very
tured whey proteins, phospholipids,
suspension lipoprotein
in a solution molecules,
of sugars, results
unadsorbed wheylower surfaceand
proteins excess,
saltsalthough the emulsion is ther-
components of the original milkfat globule membrane, and modynamically favored due to the lowering of the interfacial
any added chemical surfactants (6,93). These all compete tension and net free energy of the system.
for space at the fat surface. By controlling the adsorbing Crystallization of fat also occurs during aging, creating
material present at the time of homogenization, it may be a highly intricate structure of needle-like crystals within the
possible to predetermine the adsorbing substances and thus globule (Figure 154.18). The high melting point triglyc-
create a membrane with more favorable functional attrib- erides crystallize first, and continue to be surrounded by liq-
utes, utilizing natural proteins rather than relying on the uid oil of the lower melting point triglycerides. It has been
chemical surfactants (47). The membrane formed during reported that fat crystallization of emulsified milkfat at
homogenization continues to develop during the aging step refrigerated temperature reaches equilibrium within 1.5
and rearrangement occurs until the lowest possible energy
state is reached (95). The transit time through a homoge-
hours (6). A partially crystalline fat droplet is necessary for
clumping to occur. van Boekel and Walstra (118) found
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nization valve is in the order of 10!5 to 10!6 seconds (91). emulsion stability of a paraffin oil in water emulsion to be
Protein adsorption or unfolding at the interface may take reduced by six orders of magnitude when crystals were pres-
minutes or even hours to be complete (21). It is clear, ent in the dispersed phase. This has been attributed to the
therefore, that the immediate membrane formed upon protrusion of crystals into the aqueous phase causing a sur-
homogenization is a function of the microenvironment at face distortion of the globule (118). The crystal protrusions
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Quality and Safety of Frozen Dairy Products 465

process to establish their structure and texture. The manufacturing process for most of these products
is similar and involves the preparation of a liquid mix; whipping and freezing this mix dynamically
under high shear to a soft, semifrozen slurry; incorporation of flavoring ingredients to this partially
Not for
frozen mix; andExamination
packaging– and
Onlyfurther
for Understanding
freezing (hardening) of the product under static, quiescent
conditions. Swept (scraped)-surface freezers are used for the first freezing step, while forced
convection freezers, such as air blast tunnels or rooms, or plate-type conduction freezers are used
for the second freezing step. While this chapter overviews the basics of processing and ingredients,
the reader is referred to several recent comprehensive reviews for further details [9–14, and numerous
references contained therein].
In frozen aerated dairy desserts, ice, air, and fat each occupies distinct but interrelated phases
(Figure 19.1) and together establish the structure and resulting texture. The ice phase is of critical
importance to the quality and shelf life of frozen products. The objective of ice cream manufacturers
is to produce ice crystals that are below, or at least not significantly above, the threshold of sensory
detection at the time of consumption, 40–50 µm [9]. Consequently, the freezing steps of the manu-
facturing process and the temperature profile throughout the distribution system are the critical
factors in meeting this objective.
Ice Cream – Solid like Structure
Dispersed phase 1 – Air bubbles (Caused by overrun / foaming
INGREDIENTS of the mix emulsion)
Dispersed phase 2 – Ice crystals (Caused by Freezing of the mix)
Fat
Fat Surrounds Air bubbles –Fat partially crystallizes at low temperature and becomes a
The fat content is an indicator of the perceived quality and/or value of the ice cream. The fat component
network
of the mix of agglomerated
increases the richnessfat,
ofduring
flavorthe concomitant
of the ice cream,whipping andafreezing
produces characteristic smooth texture by
lubricating the palate, helps to give body, and aids in producing desirable meltingstructure
Network of agglomerated fat – surrounds the air bubbles and gives rise to a solid-like properties [9].
Milk fat, from cream, condensed milk blends, sweet (unsalted) butter, or anhydrous milk fat, is the
principal or only fat source for dairy ice cream formulations. Vegetable fats can also be used as fat
sources in nondairy ice cream. Blends of fats are often used in ice cream manufacture, selected to take
into account physical characteristics, flavor, availability, and cost. Palm kernel oil and coconut oil
are the most common of the vegetable fats used [12]. Regardless of the source, it is important that a

Fat globules, Not for Examination – Only for Understanding

partially crystalline

Casein micelles

Ice crystals

Mixed membrane around

fat globules of caseins
micelles, non-micellar
casein, whey proteins
and emulsifier

Partially-coalesced
fat globule network

Freeze-concentrated
unfrozen phase of
sugars, salts and
unadsorbed proteins

Air bubbles, surrounded

by protein membrane and
adsorbed fat globules

FIGURE 19.1 Schematic diagram of the structure of ice cream.

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freezing units. In this type of process, mix is drawn from the flavoring tank into a swept
surface heat exchanger, which is jacketed with a liquid, boiling refrigerant (usually
ammonia in larger scale freezers). Incorporation of air into ice cream, termed the overrun,
is a necessity to produce desirable body and texture. Overrun is carefully controlled as it
greatly affects both texture and yield. In modern systems, filtered compressed air is
4/9/18
injected into the mix at controllable rates and is dispersed in the ice cream during the freez-
ing/whipping process. Rotating knife blades and dashers keep the product agitated and
prevent freezing on the side of the barrel. Residence time for mix through the annulus of
the freezer varies from 0.4 to 2 min, freezing rates can vary from 5 to 27°C per min, and
draw temperatures of −6°C can easily be achieved. Batch freezing processes differ slightly
from the continuous systems just described. The barrel of a batch swept surface heat
Scraped–Surface Heat Exchanger

The Continuous
Ice Cream
(Barrel) Freezer

Stainless steel cover

Insulating layer
Refrigerant
Ice cream annulus
Scraper blades
Dasher (hollow,
with solid beater)

Figure 8.10 Schematic diagram of an ice cream continuous freezer. Mix enters at the rear,
freezes, and incorporates air bubbles as it passes through the ice cream annulus while being
agitated and scraped from the wall.

Freezing – Hardening

¨ Second stage of freezing: - Hardening

¤ Ice cream, following dynamic freezing and packaging is
immediately transferred to a hardening chamber (−30°C or less)

¤ Hardening Chamber – either forced convection or plate-type

conduction freezers

¤ Majority of the remaining water freezes

¤ Rapid hardening is necessary to maintain the small ice crystal size

distribution that was created in the scraped-surface freezer

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Hardening Chamber / Tunnel

Storage

¨ Following rapid hardening, ice cream storage should

occur at low, constant temperatures, usually at −25°C

¨ Storage period ranges from 0 to 9 months

¨ Ice creams are stored in cold stores

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Flavor

¨ Flavor is an important attribute of ice cream

¨ Falvour is a sensory response that has three

components:
¤ Olfaction (odor/smell)
¤ Gustation (taste)
¤ Tactual (mouthfeel)

Flavor Addition

¨ Flavors are added in at least three different ways, namely

a) Directly to mixing tank prior to freezing (ice-cream mix)
n For liquid flavors, colors, fruit purees, flavored syrup bases, or anything
else that will become homogeneous within the ice cream

b) Through a variegating pump, post-freezing (semi-frozen)

n For ribbons, swirls, ripples, revels, etc

c) Through an ingredient feeder, post-freezing (semi-frozen)

n For particulates – fruits, nuts, candy pieces, marshmallows, cookies and
bakery pieces, etc

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Quality Aspects of Ice Cream

¨ Flavor Defects

¨ Texture Defects

Flavor Defects (Based on origin)

¨ Flavoring system defects can be defined as:

¤ Lacks fine flavour, lacks flavour, too high flavour and unnatural flavor

¨ Sweetening system defects can be defined as:

¤ Lacks sweetness, too sweet, syrupy flavor

¨ Dairy ingredients
¤ Acidic, salty, lacks freshness, old ingredient, oxidized/metallic, rancid,
whey flavour

¨ Processing – cooked flavour

¨ Other Defects – absorbed from storage, stabilizer, and neutralizer

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Texture Defects

¨ Recrystallization of ice crystals – leads to a coarse, icy texture

¤ Recrystallization – Ice crystals become unstable and small ice crystals
disappear, leaving fewer and larger ice crystals during frozen storage

¤ When storage temperature fluctuates (Heat Shock) – melting and refreezing

continually occurs in the ice cream leading to this defect of iciness

¨ Lactose crystallization – leads to sandy mouthfeel

¤ Lactose crystallizes when concentration in the serum phase (unfrozen
concentrate) exceeds the solubility concentration of lactose

¤ Maximum 15.6 to 18.5% MSNF is suggested to prevent crystallization

¤ Sucrose & stabilizers inhibits lactose crystallization (higher viscosity)

Recrystallization of Ice Crystals - Electron micrograph (SEM)

A. Small ice crystals in Ice Cream

No Recrystallization – Good Quality

B. Large ice crystals in Ice Cream

Recrystallization –Defect

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Texture Defects

¨ Shrinkage – Improper handling leads to this defect

¤ Ice cream pulls away from the walls of the container

¤ Shrinkage – loss of discrete air bubbles coalesce and begin to

form continuous channels, leading to collapse of the product
itself into the channels
¤ Formulation factors like improper use of proteins, emulsifiers
and stabilizers leads to shrinkage

¤ External factors – atmospheric pressure also cause the defect

Ice Cream Freezers

¨ Batch Ice Cream Freezer

¨ Continuous Ice Cream Freezer

¨ Novelty Ice Cream Freezer

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