ICE

ICE CREAM
CREAM
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In this session, we will cover:

Ice Cream Structure

Ice Cream making process
New Processes
Raw Materials
Costs
Ice Cream Microstructure ICE
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4 phases:
FAT

AIR

MATRIX
ICE
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AIR
(30-70%)
FAT
(3-8%)
ICE
(5-30%)
MATRIX
(10-40%)

0,15mm
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Air Cell
282,905,439/litre IC

Agglomerated fat

Fat particles
25,461,489,497,136/litre IC
RAW
RAWMATERIALS
MATERIALSTANKS
TANKS ICE
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PREMIX
PREMIX
TANK
TANK
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Agitation ACADEMY
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Typical temperature-time profile for mix making 2 mins at 65C

90 Hot Water 82 - 85C

Sucrose, Stabilisers & Emulsifier

80 Corn Syrup
Temperature (C)

Sucrose Fat Colour,

Skim Flavour
70 Milk
Powder

Whey Powder
60 Rework 45C
Rework 4C

50
0 4 8 12 16 20 24 28
Time (mins)
RAW
RAWMATERIALS
MATERIALSTANKS
TANKS ICE
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PREMIX
PREMIX
TANK
TANK
RAW
RAWMATERIALS
MATERIALSTANKS
TANKS ICE
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PREMIX
PREMIX
TANK
TANK

HOMOGENISER
HOMOGENISER
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Homogenisation
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Homogenisation
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0,001mm

Fat Droplet

25,461,489,497,136
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Fat particle

Milk protein

0,001mm
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Fat particles prevented

from re-joining
by protein barrier
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Highly stable emulsion

 ICE
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Highly stable emulsion

RAW
RAWMATERIALS
MATERIALSTANKS
TANKS ICE
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HOMOGENISER
HOMOGENISER

PASTEURISER
82 deg C
30 SECONDS
PREMIX
PREMIX
TANK
TANK

4 deg C

AGEING
AGEING
TANK
TANK
 ICE
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AIR
(30-70%)
FAT
(3-8%)
ICE
(5-30%)
MATRIX
(10-40%)

0,15mm
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 ICE
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Air Cell

Agglomerated fat
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Ageing

Solidified
fat
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Ageing
Emulsifier

Liquid
Fat

Solidified
Fat
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Ageing
Emulsifier

Liquid
Fat

Solidified
fat
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High-energy impact
Emulsifier

Liquid
Fat

Solidified
fat
The Ice Cream Freezer ICE
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DASHER
CYLINDER
The Ice Cream Freezer ICE
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Air
in

Ice cream
out
Mix
in
The Ice Cream Freezer ICE
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Air
in

Liquid
Ammonia
Ice cream
out
Mix
in
 The Ice Cream Freezer ICE
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AMMONIA
GAS OUT

AIR IN

AMMONIA
MIX IN LIQUID IN ICE
CREAM
OUT
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This is the only place that Ice crystals are generated!

 How a Freezer changes Mix into Ice Cream ICE
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VISCOSITY
4 AGGREGATED
FAT
ICE CRYSTAL
NUMBER
°C

AIR CELL
SIZE
-6
TEMPERATURE

Inlet Outlet
Position in Cylinder
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5.2

5.0

4.8

4.6

4.4

4.2

4.0

3.8

3.6
20
40
60 80
80 70
60
100 50
40
120 30

Small air cells give creamier products

Pack code 5
 ICE
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Mix converted to Ice Cream with 50% overrun

50% increase
in volume
The Minor Ingredients ICE
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
The Minor Ingredients ICE
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
The Minor Ingredients ICE
ICE CREAM
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
The Minor Ingredients ICE
ICE CREAM
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ACADEMY
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
The Minor Ingredients ICE
ICE CREAM
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
The Minor Ingredients ICE
ICE CREAM
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
The Minor Ingredients ICE
ICE CREAM
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
The Minor Ingredients ICE
ICE CREAM
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ACADEMY
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
The Minor Ingredients ICE
ICE CREAM
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ACADEMY
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STABILIZERS EMULSIFIERS COLOURS FLAVOURS

WHAT ARE MAINLY POLY- MONO NATURAL eg NATURAL

THEY? SACCAHRIDES DIGLYCERIDES RED BEET, EXTRACTS
OBTAINED FROM MADE FROM FATS CAROTENE ETC
PLANTS NATURE
ARTIFICIAL IDENTICAL

ARTIFICIAL

WHY DO WE TO IMPROVE TO IMPROVE TO IMPROVE TO GET A

NEED THEM? MELTDOWN MELTDOWN VISUAL GOOD TASTE
RESISTANCE RESISTANCE AND ATTRACTION
AND CREAMINESS
CREAMINESS
 ICE
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Ultra High Pressure Homogenisation

 ICE
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Ultra High Pressure Homogenisation

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Cold Extrusion
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 ICE
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2
1

1
2 1
2
Surface area 24 Surface area 6
Volume 8 Volume 1

This has twice the surface area

per unit of volume
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ICE
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ICE
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 ICE
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BEFORE
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BEFORE

AFTER
ICE
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 ICE
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This Ice Cream is

CRAP!!!
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Ice Cream is Delicate!

It can be (and frequently is) damaged by:
Mechanical Force
Mechanical shock
High storage temperature
Thermal cycling
Reduced barometric pressure
Pressure cycling
Odors
Exposure to air
 ICE
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Water Ice products

ACADEMY
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Needle-like
Ice crystals

WATER
SUGAR
STABILISERS
COLOUR
FLAVOUR
 “Softer” ice crystal
Water Ice products structure
ICE
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(Slush freezing ) Needle-like

Ice crystals
 ICE
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FRUIT
SUGAR
WATER
STABILISERS
COLOUR
FLAVOUR
+AIR
+AGITATION
=SORBET
total solids
normally >25%
 ICE
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Sherbet
Similar to sorbet but with some
fat and MSNF (Milk Solids Non-
Fat)
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Fat in Ice Cream ACADEMY

ACADEMY

FUNCTION Fat is an important structural component

Fat improves sensory properties and melt down
resistance
SOURCE Fresh pasteurized cream
Butter or butterfat
Other fats from the Oil Processing Industry

STORAGE Vegetable fats and butterfat can be stored at :

45C for 7 days
5C for 1 month
-20C for 12 months
Cream can be stored at 5C for 3 days
ISSUES Rancidity
Nutrition
 Milk in Ice Cream ICE
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FUNCTION The Protein in the "non fat milk solids" (NFMS)

emulsifies the fat in the mix

SOURCE Concentrated skim/whole milk or skimmed

milk powder
Whey based milk replacers
STORAGE Concentrated milk (pasteurised) can be
stored for 48 hours at 5C. Skimmed milk powder
can be stored for several months if kept cool and dry
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Sugars

FUNCTION Sweetness
Depression of freezing point and thereby control of
ice content and softness
SOURCE Sucrose (Cane and Beet)
Corn Syrup (Maize)
Fructose
Lactose (Milk)

STORAGE Sucrose can be stored for long periods of time if kept dry
Corn syrup can be stored at 40-45C for up to 2 weeks

ISSUES An important component in order to control

product properties such as :
Sweetness
Softness
Lactose Crystallisation
White Spot in Water Ice
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Fruit
ACADEMY
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Fruit is added in the form of purees and Juices

Sometimes these are added in the mix tank;

care must be taken to :
Avoid damaging the milk proteins
Ensure no seeds or pips reach the
homogeniser

Aseptically packed fruit can be added

directly to the ageing (mix storage) tank
The Minor Ingredients ICE
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 Chocolate Coatings ICE
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Ingredients Sugar, Milk Powder, Cocoa, Emulsifier, Flavour,

Vegetable Fat

Function Taste, Handling of Product, Water Proofing

Application Dipping, Enrobing, Spraying

to the
Product

Important Viscosity (Fat content & Emulsifier)

Properties Setting Time (Fat Type)
Setting temperature
Used In Magnum, Cornetto, Viennetta

Other Price, Hygiene, altitude cracking, pinholing

Issues
 ICE
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The U.S. produces most of the world's soybeans and exports about half
its crop to Europe and Asia.

Monsanto opposes separation of products containing Roundup Ready

Soybeans, which means that any of the thousands of food products
containing soy material might contain genetically engineered beans. The
company even opposes labeling, so consumers will not know that they
are eating genetically engineered food.
 ICE
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GREENPEACE POLICY STATEMENT:

In the light of the known risks of introducing genetically

engineered organisms into the environment, Greenpeace is
opposed to the growing, production and marketing of
genetically engineered crops and food.

GREENPEACE RECOMMENDATIONS:

Greenpeace recommends:

that consumers, food retailers, soybean brokers and

processors demand soy products free from of
genetically engineered manipulations.
that farmers avoid the Roundup Ready Soybean and
plant only non-genetically engineered soybeans and
other crops.
Fruit Pieces
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Ingredients Fruit, Sugar (Stabiliser)

Function Texture Contrast, Appearance

Application Fruit Feeder

Important
Particle Size, Resistance to Breakdown
Properties

Used In Carte d'or, Breyers

 Nuts ICE
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Hazelnuts, Peanuts, Walnuts, Almonds etc.,

(Often chopped and/or roasted)

Function Taste, Texture Contrast

Application Vibrator feeding for toppings, Fruit Feeder for
bulk dispersion in coatings
Important
Moisture Content, Particle Size
Properties
Used in Cornetto, Carte d'or, Magnum

Other Issues Rancidity, Aflatoxin, Allergic reactions

 Wafers ICE
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Ingredients Flour, Sugar, Fat, Emulsifier

Manufactured on a Wafer Baking Machine

Function Texture contrast, Edible container

Important
Crispness (Moisture Content)
Properties

Used in Cornetto, Winner Taco

Other Issues Chocolate Spraying system is a key factor

determining wafer quality
Nutritional Assessment of Ice ICE
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Cream Products

Positive Source of Calcium

Source of Vitamins A, B2 & B12
Milk Protein is high quality
Fits in balanced diet

Negative Rich in Fat

Fat is rich in saturated fatty acids
Dairy fat contains cholesterol
Rich in Sugar
Milk-based products contain lactose
 ICE
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consumer
properties
em
u
str lsio
uc n
tur
e

fat
& appearance

milk

flavours
taste

emulsifier
colours

sugar stabiliser
i
co ce
nt
en
t
is c o sity
s ix v
& oft mat r
sw ne
ee ss
tn
es role in
s
structure
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appearance
appearance
flavour
flavour
sound
sound smell
smell
taste
taste
texture
texture
 ICE
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DEFINITIONS FOR DARK MAGNUM ATTRIBUTES

1ST BITE (no chews)

Magnum Bite Diagram CRACKING NOISE OF COATING

The amount of sharp, snapping, cracking noise made when the chocolate coating is bitten with the
front teeth.

HARDNESS OF COATING
The hardness of the chocolate coating , perceived when the sample is first bitten with the front teeth.

HARDNESS OF ICE-CREAM
The hardness of the ice-cream, perceived when the sample is first bitten with the front teeth. (Air,
sugar)

BRITTLENESS OF COATING
The extent to which the coating shatters into pieces and comes away from the ice-cream during the
1st bite with the front teeth.
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2ND BITE (6 CHEWS)

COLDNESS*
Magnum Bite Diagram The degree of cold sensation felt during 6 chews with the side/back teeth. (Ice content,
sugars, other solids, temperature)

ICINESS OF ICE-CREAM
The degree to which ice crystals are detected in the ice-cream during 6 chews with the
side/back teeth (Storage conditions, freezer conditions)

WAXINESS OF COATING
The degree to which the chocolate coating forms immiscible particles (similar to
candlewax) during 6 chews with the side/back teeth.
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3RD BITE (10 CHEWS)

Magnum Bite Diagram CREAMINESS OF ICE-CREAM

The degree to which the ice-cream is thick, smooth and miscible (like full-fat cream) after
10 chews with the side/back teeth. (fat type, structure, stabiliser)

GRITTINESS OF ICE-CREAM
The presence of sand-like particles of lactose, perceived in the ice-cream after 10 chews
with the side/back teeth.

POWDERINESS OF COATING
After 10 chews with the side/back teeth - The degree to which powdery particles are
perceived in the chocolate coating when it is rubbed across the palate with the tongue.
This powder may be from cocoa or milk powder.

MOUTHCOATING
The amount of residue of fat or powder left coating the mouth after the sample has been
spat-out or swallowed. (freezer conditions, emulsifier)

OTHER TEXTURE
The presence of another texture that has not previously been scored. Describe.
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4TH BITE (10 CHEWS)

FLAVOUR (Ice-cream)
Magnum Bite Diagram
CREAMY
The level of cream flavour in the ice-cream and chocolate mix.

VANILLA
The level of vanilla flavour in the ice-cream and chocolate mix.

BUTTERY
The level of butter flavour in the ice-cream and chocolate mix.
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5TH BITE (10 CHEWS then rub with tongue until coating melted completely)
FLAVOUR (Coating)
Magnum Bite Diagram COCOA
The level of cocoa flavour in the ice-cream and chocolate melt. This may be perceived as
‘real chocolate’ flavour.

CARAMEL
The level of caramel flavour in the ice-cream and chocolate melt. This may be perceived
as toffee or butterscotch flavour.

BITTER
The level of bitter taste in the ice-cream and chocolate melt.

OVERALL SWEETNESS*
The level of sweet taste in the ice-cream and chocolate melt.

OVERALL STRENGTH
The overall intensity of flavour in the ice-cream and chocolate melt.

OTHER
The level of another flavour in the ice-cream and chocolate melt that has not previously
been scored.
AIR
Increases the volume of the product ICE
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Increases the structural stability of the product ACADEMY
ACADEMY

FAT
Stabilises the foam structure
Contributes a “warm” eating sensation

WATER
Enables emulsification of fat
Provides ice
MATRIX
Milk Proteins (Milk Solids Non Fat)
Stabilise the fat/water emulsion
Contribute to taste
Emulsifiers
DE-stabilises emulsified fat
Enables fat to agglomerate

Stabilisers
Increase mix viscosity
Give creamier textures
Mask ice crystal detectability
Sugars
Sweeten the ice cream
Lower the matrix freezing point
Can cause “sandiness”
Flavour, Colour