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  • The Complete Technology Book on Flavoured Ice Cream (2nd Revised Edition)- Manufacturing Process, Flavours, Formulations with Machinery Details
  • The Complete Technology Book on Flavoured Ice Cream (2nd Revised Edition)- Manufacturing Process, Flavours, Formulations with Machinery Details
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The Complete Technology Book on Flavoured Ice Cream (2nd Revised Edition)- Manufacturing Process, Flavours, Formulations with Machinery Details ( New Arrival ) ( ) ( ) ( ) ( )
Author NPCS Board of Consultants & Engineers ISBN 9788178331812
Code ENI184 Format Paperback
Price: Rs 1475   1475 US$ 40   40
Pages: 448 Published 2019
Publisher Asia Pacific Business Press Inc.
Usually Ships within 5 Days
Buy Now Add to cart Add to wishlist

 

Ice cream is a frozen-food, sweet in flavor and is consumed as a dessert all over the globe. Ice-cream comes in variety of flavors in which fruits, nuts and other ingredients can be added to enhance the nutritional value and organoleptic property of the product. It is stored in the freezing- temperature and contains mild preservatives. Ice Cream is a favourite food of millions around the world. Ice Cream is a palatable, nutritious and relatively inexpensive food. 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.

The rising demand for innovative flavors, formats and growing demand for impulsiveness to consume the product in developing countries is expected to drive the market growth. The increased demand for frozen desserts in the developed countries is supporting the sale of ice creams. The developing technologies have helped in enhancing and innovating new flavors in the ice creams which has also helped in fueling up the market share of the product. Ice Cream is among the largest supermarket food categories which is generating high revenue. The global ice cream industry is a prosperous industry and the positive growth momentum has attracted food giants to diversify and expand their product lines.

 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 and texture, flavor, colour materials 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,  molded cones, ice cream cone making, success story of natural ice cream, specifications  of  ice cream plant, process flow diagram, sample plant layout and photographs of machinery with supplier’s contact details.

A total guide to manufacturing and entrepreneurial success in one of today's most lucrative food industries. This book is one-stop guide to one of the fastest growing sectors of the food industry, where opportunities abound for manufacturers, retailers, and entrepreneurs. This is the only complete handbook on the commercial production of ice cream. It serves up a feast of how-to information, from concept to purchasing equipment.

 

 

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

Importance of flavour

Colour

Optional ingredients

The Balanced Mix

Conditions 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

Minerals in Ice Cream

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

Fruit Sherbet

Ice

Novelties

Frappe

Granite

Souffle

Frozen Yoghurt

Lacto

Fruit Salad

Fancy Moulded Ice Cream

This group includes

Mellorine-type Products

Artificially Sweetened Frozen Dairy Foods

Non Dairy Frozen Dessert

Labelling Requirement Grouping

Regulatory Type Classification

 

4. INGREDIENTS OF ICE 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

Dextrose

Corn Syrup

Dried Corn Syrup

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

Stabilizers

Casein

Sodium Alginate

Carrageenan

Guar Gum

Locust Bean Gum

Sodium Carboxy Methyl Cellulose (CMC)

Pectin

Agar-Agar

Xanthan Gum

Hydroxypropy Methyl Cellulose

Other Gums

Starch

Stabilizer Blends

Emulsifiers

Type of Emulsifiers

Glycerides

Distilled Monoglyceride

Polysorbates

Polyglycerol Esters

Fruit Acid Esters

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 69

Flavours for Frozen Desserts

Vanilla

Imitation Vanilla Flavourings

Consistency in Vanilla Quality

Vanilla Ice Cream

Chocolate and Cocoa

Chocolate Ice 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

 

6. ICE CREAM MIXER-PREPARATION PROCESSING

AND MIX CALCULATIONS 85

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

Weighing the Concentrated Dairy 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

 

7. THE FREEZING PROCESS

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

Stiffness

Ink

Wax

Adhesive

Wax Content

Odour and Taint

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

The Hardening Process

Factors Affecting 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

Water Chelating Agent

Emulsifiers and 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

Colour

Package

Melting Quality

Defects of Melting 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

Candy Ice cream

Variations

Peppermint Stick

Butter Crunch

Peanut Brittle

Toffee

Mint Chips

Mithai Ice Cream (Gulabjamun)

Mithai Ice Cream (Rasogulla)

Mithai Ice Cream (Gajar Halwa)

Chocolate Ice Cream

Chocolate Malt

Chocolate Malt and Nuts

Chocolate Toffee

Chocolate Cool

Fruit Ice Cream

Variations

Banana

Pineapple

Apple

Orange

Orange Pineapple

Lemon

Grape

Custard Apple

Date

Sapota

Mango

Strawberry

Blueberry

Raspberry

Nut Ice Cream

Variations

Butterscotch

Almond Walnut

Almond Tofee

Peanut

Caramel Nut

Fruit and Nut

Coconut Pineapple

Tutti-Frutti

Banana Nut

Variegated or Rippled 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

Fluid Whole and Skim 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

Oranges and Lemons

Bananas and 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 Iice Cream

Sweeteners for Ice Cream

Ice-Cream Stabilizers

Flavouring Materials

Preparation of 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

Preparation of Sample

Procedure

Gerber Test

Apparatus and Reagents

Preparation of Sample

Procedure

Determination of Total Solids

Mojonnier Total Solids Test

Procedure

AQAC Official Method (AoAC International, 2000)

Determination of Acidity in Plain Ice Cream Mix

Determination of Free Fat in Ice Cream (Free Fat Estimate or FFE Value)

Apparatus and Reagents

Procedure

Calculation

Chromatographic Analysis

Stability to Heat Shock

Meltdown Test and Shape Retention

Farrall Homogenization Index

Measurement of Viscosity

Pipette Method

Borden Flow Meter Method

Brookfield Viscometer

Calculation

Test for Ammonia Leaks

Surface Tension

14. ICE CREAM NOVELTY IMPULSE PRODUCTS 255

Molded Novelties

Extruded Novelties

15. ICE CREAM SHELF-LIFE 259

Temperature Fluctuations and Ice Recrystalliation

The Role of Stabilizers

Maintaining Shelf-Life

16. ICE CREAM INGREDIENTS 263

Milkfat ( or "Butterfat") /FAT

Milk solids-Not-Fat

Lactose Crystallization

Sweeteners

Stabilizers

Locust Bean Gum

Emulsifiers

Polysorbate 80

 

17. MIX CALCULATIONS FOR 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 FREEZING

PROCESS

The Process of Crystallization

Importance of Crystallization Rate

Importance of Temperature Fluctuations and

Re-Crystallization

Formation of the Glassy Phase in Frozen Foods

Formation of a Dilute Glass

 

20. ICE CREAM MANUFACTURE

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

 

22. HOMEMADE ICE CREAM

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

 

24. AUTOMATIC ICE CREAM BAKING MACHINE

AGC-SERIES

Features

AGC 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

26. SAMPLE ICE CREAM CONE DRAWING 331

Design for Cone Diameter 30-40 mm

Design for Cone Diameter 40-50 mm

Design for Cone Diameter 50-56 mm

Design for Sugar Conges

Design for Cups

 

27. MOLDED CONES & CUPS

Process & Machines

 

28. ICE CREAM CONE MAKING

Product & Its Application

Market

Raw Material Requirements

Manufacturing Process

Wafer Cone Machine

Technical Parameter

Wafer Cone/Cup Pictures for Reference, Other Size & Shape

can be Customized

 

29. SUCCESS STORY OF NATURAL ICE CREAM

About Natural Ice Cream

Four Ps of Naturals ice cream

Product

Price

Place

Promotion

Success and the Future

 

30. SPECIFICATIONS OF ICE CREAM PLANT

1. Pasteurising: 200 Ltr

2. Milk Pump with Filter

3. Homogeniser

4. Ice Cream Mix Phe

5. Cooling Tower

6. Ageing Vat

7. Flavour Tank

8. Continuous Freezer

9. Fruit Feeder

10. S.S. Piping for Ice Cream Mix Plant

11. Skid For Ice Cream Mix Plant

12. Control Panel

13. Hardner Tunnel Model

Equipments and Machinery for Ice Cream Plant

(200 LPH)

Technical Specification

 

31. PROCESS FLOW DIAGRAM

 

32. SAMPLE PLANT LAYOUT

 

33. PHOTOGRAPHS OF MACHINERY WITH SUPPLIER’S CONTACT DETAILS

 

RELATED PRODUCTS

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Working Capital Requirement Per Month
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Turnover Per Annum
Share Capital
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Annexure 1:: Cost of Project and Means of Finance
Annexure 2:: Profitability and Net Cash Accruals
  • Revenue/Income/Realisation
  • Expenses/Cost of Products/Services/Items
  • Gross Profit
  • Financial Charges
  • Total Cost of Sales
  • Net Profit After Taxes
  • Net Cash Accruals
Annexure 3 :: Assessment of Working Capital requirements
  • Current Assets
  • Gross Working. Capital
  • Current Liabilities
  • Net Working Capital
  • Working Note for Calculation of Work-in-process
Annexure 4 :: Sources and Disposition of Funds
Annexure 5 :: Projected Balance Sheets
  • ROI (Average of Fixed Assets)
  • RONW (Average of Share Capital)
  • ROI (Average of Total Assets)
Annexure 6 :: Profitability ratios
  • D.S.C.R
  • Earnings Per Share (EPS)
  • Debt Equity Ratio
Annexure 7 :: Break-Even Analysis
  • Variable Cost & Expenses
  • Semi-Var./Semi-Fixed Exp.
  • Profit Volume Ratio (PVR)
  • Fixed Expenses / Cost
  • B.E.P
Annexure 8 to 11:: Sensitivity Analysis-Price/Volume
  • Resultant N.P.B.T
  • Resultant D.S.C.R
  • Resultant PV Ratio
  • Resultant DER
  • Resultant ROI
  • Resultant BEP
Annexure 12 :: Shareholding Pattern and Stake Status
  • Equity Capital
  • Preference Share Capital
Annexure 13 :: Quantitative Details-Output/Sales/Stocks
  • Determined Capacity P.A of Products/Services
  • Achievable Efficiency/Yield % of Products/Services/Items
  • Net Usable Load/Capacity of Products/Services/Items
  • Expected Sales/ Revenue/ Income of Products/ Services/ Items
Annexure 14 :: Product wise domestic Sales Realisation
Annexure 15 :: Total Raw Material Cost
Annexure 16 :: Raw Material Cost per unit
Annexure 17 :: Total Lab & ETP Chemical Cost
Annexure 18 :: Consumables, Store etc.,
Annexure 19 :: Packing Material Cost
Annexure 20 :: Packing Material Cost Per Unit
Annexure 21 :: Employees Expenses
Annexure 22 :: Fuel Expenses
Annexure 23 :: Power/Electricity Expenses
Annexure 24 :: Royalty & Other Charges
Annexure 25 :: Repairs & Maintenance Exp.
Annexure 26 :: Other Mfg. Expenses
Annexure 27 :: Administration Expenses
Annexure 28 :: Selling Expenses
Annexure 29 :: Depreciation Charges – as per Books (Total)
Annexure 30 :: Depreciation Charges – as per Books (P & M)
Annexure 31 :: Depreciation Charges - As per IT Act WDV (Total)
Annexure 32 :: Depreciation Charges - As per IT Act WDV (P & M)
Annexure 33 :: Interest and Repayment - Term Loans
Annexure 34 :: Tax on Profits
Annexure 35 ::Projected Pay-Back Period And IRR