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Storage department is divided in to two types: - 1) Cold storage

2) Dry storage.

1) Dry store:-

In dry store, raw materials required for ice-cream production, as well as

packaging materials are stored. The raw materials like all fruits pulp, dry-fruits,
flavors, essence, emulsifiers and stabilizers, sugar, colors, chikkis etc. are stored.

Machines available in dry store:-

A] Oven:-

a) It is used for roasting of dry fruits.

b) It consists of 15 trays; the capacity of each tray is around 10 kg.
c) The temperature of oven is adjusted as per requirement.

B] Metal separator:-

a) It is used to separate small particles of metals that may come in dry
fruits.

C] Grinders:-

a) There are two grinders in store room.

b) Before roasting, the dry-fruits are grinded to small pieces from the
grinders.

D] Weighing balance:-

a) The main purpose of weighing balance in store room is that after
unloading the raw material it is weighed and the weighted material is
being issued to production.
b) The capacity of weighing balance is around 150 kgs.
rocedure followed in Dry store:-_

1) When raw material received challan slip comes from gate to
the store department, a store control tests slips is made and
send to Quality control laboratory.
2) An accepted / rejected report is given to the store department
after performing various required quality control tests from
Quality control laboratory.
3) Then unloading of raw material is done.
4) Then entry is done in Goods Inwards Register and Goods
Received Note i.e. GRN.NO. is given, and is forwarded to
various departments.
5) Further processing of raw materials ( i.e. dry-fruits) is done.
It is done in three steps, they are as follows:-

Cleaning

Roasting

Grinding

2) Cold store:-

In cold store, final product that is the different varieties of ice-creams are
stored. Cold store comes under the Dispatch Department.

The order taken from the distributors by federation member is given to

dispatch committee and then the uploading is done and sent to the distributors.
 


roduction is divided into two sections:- 1) Ice-cream mix section.

2) rocessing section.

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Amul ice-cream mix:-

i. Fat
ii. SNF
iii. Sugar
iv. Stabilizer & Emulsifier



igh fat milk is received in receiving tank.

re-heating.

Selection of ingredients.

Figuring the mix.

Making the mix.

Filteration [carried out in duplex filter]

 Balance tank.

omogenization.

asteurization.

Cooling.

Chilling the mix.

Storage tank.

Forwarded for further production process as per requirement.

1] Receiving of high fat milk:-

igh fat milk is received and several quality control tests are carried out
like fat, SNF, acidity etc. and then it is stored in receiving tank.

2] re-heating:-

a) reheating is carried out at 50ºc to 60ºc.

b) reheating is done for proper dissolution of ingredients.

3] Selection of ingredients:-

The selection of ingredients depends on:-

a) Availability of milk products.

b) erishability of the products.
c) Convenience in handling.
d) Effect on flavor, body and texture of ice-cream
e) Cost and,
f) Equipment available.

The ice-cream mix ingredients include:-

igh fat milk:-

a Enriches the flavor.

a roduces characteristic smooth texture.
a elps to give body to the ice-cream.

Milk solids-not-fat:-

a Improve the texture.

a elps to give body.
a A higher overrun without snowy or flaky texture.
a A comparatively easy source of solids.
 Sugar:-

a Improves the texture.

a Enhances the flavor.

Stabilizer & Emulsifier:-

They are togetherly used.

a) Stabilizer:-
a ery effective in smoothening the texture.
a ery effective in giving body to the product.
a elp to preserve emulsions.
b) Emulsifier:-
a These are mainly used to improve upon and provide a uniform
whipping quality to the mixture, and to produce a drier ice-
cream with smoother body and texture.

4] Figuring the mix:-

A knowledge of calculation of ice-cream mix is helpful in properly

balancing a mix, in establishing and maintaining uniform quality and in producing
ice-cream that conforms to legal standards.

On the basis of fat and SNF values figuring of mix is done.

5] Making the mix:-

In order to make good ice-cream, the milk products and other ingredients
must be first selected and combined so as to produce the desired body and a
delicately blended flavor.

Obviously the selection of good, wholesome ingredients and calculations

of a satisfactory composition precede the mixing of the ingredients in a vat. Where
they can be heated to facilitate dissolving, blending and pasteurization.
6] Filtration:-

Filtration is carried out in duplex filters to remove foreign material if any.

7] Balance tank:-

Then the mix is passed through balanced tank for balancing properly the
constant flow.

8] omogenizing the mix:-

omogenization of ice-cream mix is essential. The main purpose of

homogenization is to make a permanent and uniform suspension of the fat by
reducing the size of the fat globules to a very small diameter, preferably not more
than 2µ.

The advantages of homogenization are:-

a It prevents fat separation during storage.

a roduces more uniform ice-cream with a smoother texture.
a Improves whipping ability.
a Shortens ageing period.
a Decreases the risk of churning occurring in the freezer, and
a |eads to the use of slightly less stabilizer.

The pressure required for homogenization depends upon several

factors:-

a Desired viscosity.
a Composition of the mix.
a Stability of the mix.
a Temperature used, and
a Construction of the homogenization machine.
U] asteurization:-

roper pasteurization of all ice-cream should be compulsory after

homogenization because this process destroys all pathogenic bacteria¶s, thereby
safeguarding the health of the consumer.

The advantages of pasteurization are:-

a It renders the mix completely free of pathogenic bacteria.

a It dissolves and helps to blend the ingredients of the mix.
a It improves the flavor.
a It improves keeping quality, and
a It produces a more uniform product.

asteurization is carried out by TST [igh Temperature Short Time]

method.

10] Then cooling of mix is done, which is most important before storage.

11] Storage tank:-

Then the ice-cream mix after cooling is stored in storage tank and used
as per required.



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Storage tank

Flavouring tank

Freezing

Addition of nuts [if required]

Overrun in ice-cream

acking & filling

ardening of ice-cream

Storage

Dispatch
12] Flavouring tank:-

Ice-cream mixed is passed from storage tank is collected in flavouring tanks

and again mixed with required colors and flavors for the particular ice-cream
product.

13] Freezing:-

Freezing is one of the most important operations in the making of ice-cream

for upon it depends the quality, palatability and yield of the finished product.

The freezing process is as follows:-

a) The mix is added with color and flavouring materials at

the freezer first.
b) Then they are quickly frozen to incorporate air in such a
way as to produce and control the formation of small ice-
crystals.
c) When the ice-cream is partially frozen to a certain
consistency [i.e. semisolid], it is drawn from the freezer
and packed in the required packaging material and quickly
transferred to cold storage where freezing and hardening
processes are done.

The function of freezing process or main aim of freezing process is to

freeze a portion of the water of the mix and to incorporate air into the mix.

The advantages of continuous freezing are as follows:-

a) |ess stabilizer needed.

b) A shorter ageing time is possible.
c) |ess flavouring material is needed.
d) Smoother ice-cream is obtained.
e) A more uniform yield is obtained with less variation between
packages.
14] Addition of nuts:-

According to the variety of ice-cream product, addition of nuts is done as

required after freezing.

15] Overrun in ice-cream:-

Overrun is usually defined as the volume of the ice-cream obtained in

excess of the volume of mix. It is usually expressed as percentage. This increased
volume is composed mainly of the air incorporated during the freezing process.
The amount of air which is incorporated depends upon the composition of the mix
and the way it is processed; and it is regulated so as to give that percentage of
overrun or yield which will give the proper body, texture and palatability necessary
to a good quality product.

Too much air in ice-cream will produce snowy, fluffy, and unpalatable
ice-cream while too low air will produce soggy and heavy product.

16] acking & Filling:-

From the freezer the semi-solid ice-cream is filled in the containers

which give it desired shape or size for convenient handling during the hardening
and marketing processes.

The packaging materials for ice-cream should be as follows:-

a rotection against contamination.

a An attractive appearance.
a Ease of opening and reclosure.
a rotection against moisture loss and temperature
fluctuations.
a Most bulk ice-creams is packed in plastic coated
cardboard boxes for protection against moisture and
oxygen [air].

Retail ice-cream is packaged in cups, sticks or bars, plastic moulded

different shapes containers etc.
17] ardening of ice-cream:-

When ice-cream is drawn from the freezer and taken it into a container
it is quickly or necessary to be placed in hardening tunnel, because the ice-cream
has a semi-solid fluid consistency and not stiff enough to hold its shape. Therefore,
the freezing process is continued during hardening until the temperature of the ice-
cream reaches -18ºc.

18] Storage / Cold storage:-

After the ice-cream is hardened it is stored in cold storage, here the

packages should be closed properly, to delay changes in ice-cream temperature.








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reparation of ice-cream mix.

Ice-cream is then mixed in flavouring tank by adding required flavors and colors in
it.

assing through the freezer.

Filling the cone

[it is done in three steps]

a) Spraying of chocolate slurry inside the cone.

b) Filling the semi-solid ice-cream in the cone.
c) Chocolate and nuts topping.

acking of cone.

Spiral hardening of cone / ice-cream.

Cold storage.
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reparation of ice-cream.

Mixing the mix in flavouring tank by adding required flavors.

assing it through freezer.

Filling the semi-solid ice-cream in required containers in the swirl manner.

acking.

ardening of ice-cream.

Cold storage.
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Ice-cream mix preparation.

Adding of probiotic bacteria and flavors required to the mix.

Freezing.

Filling the semi-solid ice-cream in required containers.

acking of material.

ardening.

Cold storage.

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ere various quality control tests have been carried for raw materials, ice-cream
mix, packaging materials and finished products. They are as follows:-



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ackaging material Weight, height, volume, dimension,
size, printing and lamination, GSM,
thickness, length, width, color, BO
test, OD, ID.
Dry fruits O.T, moisture
Kesar Moisture, ash content, floral waste.
igh fat milk Fat% , acidity% , SNF% , temperature,
O.T, COB.
Skimmed milk powder Fat% , moisture% , total solids, total
ash, titrable acidity, protein
otable water Total hardness, residual chlorine,
turbidity, microparameter, chloride,
fluoride.
Sugar OT, moisture, sucrose%
Canned fruits & pulps OT, brix, total solids, acidity, drained
weight, microbiological tests, visible
mould growth
flavors Specific gravity
Stabilizer & Emulsifier viscosity