The ice cream business is very promising. There are many reasons for this. First of all, the product produced is very popular. He is loved by both adults and children. Every grocery store is ready to offer dozens of names of this cold delicacy. That is why the development of an ice cream business is a promising and winning idea.

Ice cream production technology on industrial equipment

The purchase of equipment for the production of ice cream is a crucial step, before which it is necessary to get acquainted with the production technology. The products that will be needed to make a treat are well known to everyone: sugar, milk, water, fruits and berries. You will also need various additives: vegetable fats, stabilizers, emulsifiers and dyes.

The production technology consists of the following stages:

• Mixture preparation.
• Filtration, homogenization.
• Freezing.
• Hardening and rehardening.
• Glass production.
• Packing.

Mixture preparation. The water fraction is mixed with the fat component. For this you need:

• containers;
• reservoirs;
• containers.

Liquids must be heated to 45 degrees before mixing. Equipment is also used to simplify the mixing process.

Filtration, homogenization

The resulting mixture is passed through filters to remove lumps and debris trapped in the mixture. Then the path of raw materials lies on the pasteurization-cooling plant. About a minute at high temperature - and the mixture becomes whipped and thick.

Further, the product is cooled in the tanks intended for this purpose. As an aid, use cold water, ice, a refrigerant that creates a very low temperatures. In this state, the future ice cream settles for up to 2 days.

Freezing

The cooled mixture is frozen again, but after saturation with air.

Hardening and rehardening

Occurs under the influence of air flow, the place of the procedure is the freezer. At the exit, the finished product should have a temperature of 12 degrees. Upon reaching this temperature, the product settles in the freezer for another 2 days.

Cup production

A separate line is required. Can be used for baking different recipes, the shape of the cups varies. There are several technologies: glasses are baked single-layer and double-layer.

Packing

This process is carried out automatically. After pouring, the delicacy is covered with icing or other ingredients, such as nuts. After freezing in the chamber, the product is packed and sent to the store.

Technical equipment of the process

A mini-factory is a large part of the cost of starting any business. Ice cream production lines are no exception. In order to become an ice cream producer, an entrepreneur must have funds in the amount of at least 2,500,000 rubles. The capacity of a line with such a cost is no more than one ton of product per shift.

If the budget is limited, then you can buy a less powerful line by spending 1,500,000 rubles on it. In this case, you can count on 0.5 tons of product per day. It is possible to reduce the expense item for the purchase of equipment if all parts of the line are purchased separately, but for this it is necessary to have all necessary knowledge and the process of installing the line to deal with personally.

Regardless of whether it will be a ready-made mini-factory or a set of necessary units purchased separately, to make ice cream you will need:

• mixer;
• pasteurizer;
• filter;
• homogenizer;
• various storage containers;
• oil melter;
• stop valves;
• pump;
• refrigerating chambers;
• freezer.

The listed units are designed to receive finished product. It should be understood that ice cream needs to be packaged and packaged, and this additional expenses for the purchase of equipment. They can reach 500,000 rubles. This cost of lines is considered quite high, but with a competent approach and well thought out marketing plan pay off quickly. If this cost is too high, then you should think about another option for doing such a business.

Small business devices

If the costs of opening a full-fledged ice cream production line are unbearable, you should think about purchasing a soft ice cream production machine. It's called a freezer. You can use it at home.

The device has a lot of technological capabilities. He knows how to mix ingredients, freeze them and pack ice cream. Everything you gotta do service staff- this is a dilution of the dry mixture with water and refueling in a special bunker. The contents will quickly increase in volume, and its temperature will be lower - 8 degrees. A good freezer can produce up to 300 servings of soft ice cream per hour.

Cost of equipment and production costs

Before talking about the payback of the business, you need to calculate the amount that will need to be invested in the project. All the calculations presented here are approximate, but it will still help to get an approximate picture and see the future. An entrepreneur who decides to start producing ice cream will need about 2,500,000 rubles.

There is an option to reduce costs by buying a used line, but this can be even more expensive later on as old lines can break down.

The average capacity of the line can produce about 0.5 tons of products per day. There will be at least 22 such shifts per month. With simple arithmetic calculations, it turns out that about 11 tons of ice cream can be obtained per month. The average wholesale price is 170 rubles per kg. In this scenario, the monthly revenue will be 1,870,000 rubles.

Subtracting from the amount received the cost of raw materials, wages, transportation costs and rental of premises, we get a net profit of about 100,000 rubles. In this scenario, the production of ice cream can be considered profitable, the equipment will pay off in 22–24 months. Among entrepreneurs, such indicators are considered good.

Advantages of this type of business

Everyone loves ice cream. The stability of demand can be easily explained by the popularity of the product, but in a certain period the demand for it increases significantly: this is the time from May to October. When planning the launch of the line, it is recommended to take this into account. Optimal time start work - March.

In this case, at the time of peak consumption, the sale of the product will be well established.

In this industry, competition for high level. Recently, manufacturers have shown imagination and come up with new combinations of flavors. This is done in order to win over its group of consumers. Against the backdrop of such a variety, a simple classic popsicle sometimes delivers even more joy than the taste of salted caramel or cheese.

When deciding to open a mini-ice cream factory, you need to consider the following:

• the product must be original;
• taste qualities must meet the standards;
• packaging and design should attract attention;
• the marketing campaign should be quite aggressive, since the product is new and not yet known to the consumer.

ABSTRACT ON BIOTECHNOLOGY

Ice cream production process and equipment for its production

MOSCOW 2006

INTRODUCTION

Ice cream- a delicacy product with a significant cooling effect, high nutritional, biological and energy value. Thanks to this, as well as excellent taste, it is very popular among the population, especially among children.

The global industrial production of ice cream reaches approximately 11 million tons per year.

The "precursors" of ice cream are fruit juices mixed with snow or ice, natural or sweetened, which were known in ancient times. So, in China, fruit juices were frozen about 3 thousand years ago, and Alexander the Great, during campaigns in Persia and India in the 4th century BC, used fruit juices with snow. The ancient Greek physician Hippocrates wrote about the consumption of frozen fruit juices in the 4th century BC. The same ice cream was prepared in the 1st century AD at the court of the Roman emperor Nero.

In Europe, ice cream is closer to modern form became known at the end of the 13th century, when the Venetian traveler Marco Polo brought a recipe for this product from China. At the Italian courts, ice cream was considered one of the most delicious dishes.

Gradually, the secrets of ice cream technology become known in other countries. In 1660, the Italian Francesco Procopio opened an ice cream trade in Paris, and in 1676 an ice cream corporation was already established in this city, numbering 250 entrepreneurs.

Until the middle of the 18th century, ice cream was sold only in the summer, and in 1750 the successor Procopio de Buison began to make ice cream all year round. Soon other ice cream makers followed his example, and dairy products were also used to make ice cream.

The first mention of the sale of ice cream in the United States dates back to 1777, and in 1851 the American J. Fussell organized its wholesale production in Baltimore, and then in other cities.

In Russia, ice cream first appeared on the menu of the royal court. The book "The Newest and Complete Cookbook", published in Moscow in 1791, gives instructions on how to make ice cream from cream, chocolate, lemons, currants, cranberries, raspberries, oranges, egg whites, cherries. In 1845, a merchant Ivan Izler was granted a patent for an ice cream machine. However, the beginning industrial production ice cream in our country is considered to be 1932, when the first ice cream shops were created in Moscow at the city dairy plant and refrigerator No. 2. In 1932, these two enterprises produced 20 tons of ice cream, in 1937 the USSR produced 300 tons of this product, and in 1940 the total output was 82 thousand tons. Patriotic War ice cream was almost non-existent. Already by 1950. pre-war production was cut off, and in 1989 about 750 thousand tons of it were produced in our country, or 2.7 kg per capita per year.

Ice cream is produced according to complex technology in specialized factories or in workshops at dairies and cold storage plants, and delivery to trading network and implementation - using dry ice or refrigerated road transport and counters with mechanical cooling. Such ice cream is called tempered. If necessary, hardened ice cream is stored for several months in refrigerators. Its temperature upon release from the enterprise should be -12 .... -14 ° C, and optimum temperature use of hardened ice cream minus 9 o C.

Ice cream- whipped sweet food product made from milk, dairy and cream products, butter, whey, buttermilk, products with a complex raw composition, oils, fats and proteins of non-dairy origin with the addition of other ingredients and substances or from water, sugars and / or their substitutes with the addition of other ingredients and substances by freezing.

Under production conditions, hardened ice cream is made. At enterprises Catering produce soft ice cream, which resembles cream in consistency.

BASIC ICE CREAM PRODUCTION TECHNOLOGY

Preparing the mixture

The preparation of an ice cream mixture generally consists of the steps of preparing an aqueous phase and mixing the fat fraction and solids of the mixture in a flow or batch process. To mix raw materials in the preparation of mixtures for ice cream, universal heat-exchange tanks, cheese-making baths, long-term pasteurization baths, tanks for heat treatment of milk and other tank equipment are used. Baths equipped with a steam bubbling jacket and a high-quality mixing device can also be used for pasteurization and cooling of the mixture. The water phase of the ice cream mixture - milk and / or water is preheated to a temperature of 40..45 ° C using plate heaters or other available heat exchange equipment. For the production of solids and fats, devices such as dispersers are used. Depending on the performance of the mixture preparation area, appropriate equipment is used to automate and simplify the process: screw lifts, oil melters, bunkers, etc.

Filtration

After preparation, the mixture is filtered. Typically, two-section capacitive filters are used. The filtration process is fundamentally necessary, because. the subsequent equipment critically perceives the undissolved lumps of solids present in the mixture, not to mention burlap and other "results" production activities enterprises.

Pasteurization

Pasteurization of the mixture on a plate pasteurization-cooling unit is carried out at a temperature of 80...85°C with a holding time of 50...60 sec. When pasteurized in containers heat exchangers periodical action the following modes are applied: 68...72°C, exposure 25...30 min; 73-77°С, exposure 15...20 min; 83-87°С, exposure 3...5 min.

Homogenization

Needed to stabilize the emulsion. It is carried out at a temperature close to the temperature of pasteurization. The greater the mass fraction of fat in the mixture, the lower the homogenization pressure. In the production of ice cream, it is recommended to use a two-stage homogenization. Depending on the type of ice cream mixture, the following homogenization modes are used - from 7 to 12.5 MPa for the first stage and 4.5-5.0 MPa for the second stage. The use of the process of homogenization of the ice cream mixture allows to achieve the required degree of overrun and good consistency of the finished product.

Cooling

After homogenization, the mixture is cooled to t 2...60°C. For this purpose, plate-type pasteurization-cooling units, plate and shell-and-tube coolers, VDP, cream-ripening baths, etc. are used. The mixture is first cooled running water, then ice water with t 1 ... 2 ° C or coolant (brine) with t not higher than -5 ° C.

Storage and maturation

The mixture is sent to tanks or cream-ripening baths, where it is stored at t 4...6°C for no more than 24 hours, at t 0...4°C for no more than 48 hours. Storage is an obligatory stage of the technological process only for ice cream mixtures prepared using gelatin (stabilizer). Such mixtures must be kept at t not higher than 6 ° C, 4 ... 12 hours.

Freezing the mixture

During freezing, the mixture is whipped (saturated with air), partially frozen. Continuous or intermittent freezers are used. The mixture enters the freezer with t 2...6°C, t of ice cream at the outlet should not be higher than -3.5°C, with the exception of ice cream produced using eskimogenerators. The overrun of ice cream is 40..60% depending on the type of ice cream and the freezer used.

Hardening and rehardening of ice cream

After freezing, ice cream is immediately subjected to further freezing (hardening) as soon as possible. Packaged ice cream is hardened in a stream of air at t from -25 to -37°C in special freezers, as well as in metal molds in eskimogenerators. The temperature of ice cream after hardening should not exceed minus 12°C. Additional hardening is carried out in hardening chambers or storage chambers for 24 ... 36 hours. Hardened ice cream is placed in a storage room.

Equipment for the preparation of a mixture of ice cream

Currently, the preparation of an ice cream mixture can be divided into two technologies: batch and mixture preparation in a stream.

Batch technology

Portion technology is widely used in the production of ice cream mixtures at small and medium-sized enterprises, where the line capacity is from 100 to 1250 kg/h for the finished mixture. The essence of the technology is the preparation of a mixture of ice cream from the main components - liquid phase, solids, fatty phase in capacitive heat exchangers with simultaneous stages of creating a dispersed emulsion and pasteurizing the mixture. To solve this problem, long-term pasteurization baths, universal tanks, modified cheese-making baths, specially designed baths with a steam jacket and an appropriate type of mixer are used.

In this article:

Ice cream is loved by everyone: both adults and children. And so it was at all times, and its history goes back more than 5000 years. The ice cream business is characterized by seasonal profits. large factories consider this business very profitable, like any properly organized production.

The organization of the production of ice cream includes the investment of capital and variable costs.

For a potential owner of this type of business, it is important to purchase an inexpensive, and at the same time high-quality production line. Depending on the method of production, ice cream is divided into hardened (creamy), soft and homemade.

The ice cream production process on an industrial scale consists of the following steps:

• preparation and mixing of the raw mass;
• filtration;
• pasteurization;
• homogenization;
• cooling;
• storage and final maturation;
• freezing;
• packing;
• hardening;
• package.

The technological scheme for the production of ice cream is as follows:

Also, if desired, you can buy a line for the production of sticks (Fig. 3), or purchase them from suppliers.

Rice. 3. Line for the production of ice cream sticks

Required raw material base

Milk is the main raw material(whole, fat-free, dry whole and fat-free, condensed with sugar) and dairy products (cream, whey and butter).

It is also necessary to add sugar, vegetable fats, aromatic fillers, stabilizers and emulsifiers. The latter are responsible for the lush structure of the product even in the process of melting.

Today, many large manufacturers use a more modern and convenient component: a stabilizer-emulsifier. It increases viscosity, evenly distributes fine air bubbles throughout the mixture and imparts a creamy feel to the finished product.

Another important ingredient is the frosting. It comes in chocolate, white or fruit. For its manufacture, cocoa butter, vegetable fat, powdered sugar, cocoa powder, emulsifiers, milk powder and a variety of flavors are used.

Cream ice cream production technology

All the necessary ingredients (according to the recipe) should be mixed using a blender, dispersant or turbo mixer. It is first necessary to heat the water component to a temperature of 40 - 45 ° C (milk or ice cream). This can be done using a variety of capacitive equipment: long-term pasteurization baths, cheese-making baths, tanks for heat treatment of milk. Such jacketed containers can subsequently be used for pasteurization and cooling of mixtures. Now the prepared mixture should filter out- there is a removal of undissolved particles or clots of stabilizers.

IN pasteurization process enzymes are destroyed and pathogenic microorganisms are destroyed, which can worsen the taste and aroma of the future ice cream. It is produced on a pasteurized cooling machine at a temperature of 80°C with a holding time of 50 seconds (or at a temperature of 95°C without holding).

Now has come homogenization step– large particles of fat are crushed, and accordingly the homogeneity of the mixture increases. At a temperature of 85°C, this process takes place in two stages. The first stage is characterized by pressure from 7 to 12.5 MPa, and the second - from 4.5 to 5.0 MPa.

The resulting mixture is then cool down to a temperature of 3°C using a cooling unit. You can also use containers for ripening, and cool down first with cold and then with ice water.

Now the mixture should send to tanks, and in the process of slow stirring, the future ice cream will ripen at a temperature not higher than 6 ° C from 3 to 24 hours (or no more than 48 hours at a temperature of 0 - 4 ° C). The fat globules will harden, the stabilizer will swell, and the mixture will acquire viscosity and the ability to bind air during the freezing process.

It is important to note that the higher the concentration of solids and the rate of freezing, the smaller the crystals and the more delicate the structure of the ice cream produced.

The next step in the ice cream production process is freezing. Here the mixture is frozen and whipped with air, subject to continuous stirring. Small bubbles saturate the resulting mass and an ice cream structure is formed, which is finally formed during the subsequent freezing of the product. The mixture that comes out of the freezer should have a thick (creamy) consistency.

Now you can start packing– it can be produced on automatic or semi-automatic lines. Dosing into cups or waffle cones takes place on universal conveyors, and subsequent freezing takes place in hardening chambers (from -25°С to -37°С). This is a short-term process, otherwise the ice crystals will noticeably increase in size. Sometimes, in order to save time, packaging is combined with hardening due to universal equipment, which combines a conveyor, an extrusion line and an eskimogenerator. After hardening, the ice cream temperature should not exceed -10°C.

Pack the finished product in carton boxes or corrugated boxes. Then they should be stored in refrigerators at a temperature of -20°C. All kinds of conveyors or transport systems are used to move ice cream to the warehouse.

Hardened ice cream is distinguished by its appearance, filling and type of packaging. Depending on the type and filler, there are basic and amateur types. The first include dairy, creamy, ice cream, aromatic and fruit and berry. amateur species are distinguished by a smaller volume of production and a variety of species (about 50 options).

Here is an example of some of them:

• citrus(due to chicken eggs in its composition it has a high biological value);
• honey - with the addition of natural honey;
• penguin- fruit and berry base in chocolate glaze and much more.

Technological process of soft ice cream production

Soft ice cream differs from hardened ice cream in that it is made under different conditions. This variety is already ready after leaving the freezer and is not subjected to further freezing. Often it is prepared immediately before use and in the presence of the buyer - in freezers. The raw materials are special dry mixes, water and juice.

The temperature of soft ice cream is not as low as hardened ice cream (4-6°). And even with the naked eye, you can see a delicate and creamy texture.

For no reason a large number frozen moisture content, the presence of air in the form of bubbles, soft ice cream has a specific taste and aroma. An interesting feature is that the raw material is practically no different from the ingredients of hardened ice cream. And thanks technological features cooking, it is much better absorbed by the body.

Making homemade ice cream

With insufficient financial resources, it will be preferable to create a small ice cream factory right in your kitchen. Lack of rent is the main advantage this method business.

To do this, you will need a roomy refrigerator, food processor, plastic tableware and the raw material itself. And according to the recipe, you can proceed to the manufacture of the first batch of the product. Of course, nowadays there are a huge number of recipes. Let's give an example of one of them - milk ice cream with vanillin.

Required components: 1 liter of milk, 300 grams of sugar, 2 vanilla powder, 6 eggs.

Milk should be boiled with sugar. Add hot milk to beaten eggs, stir, and pour in a thin stream into boiling milk, stirring the mixture continuously. We make a weak fire and beat until weak bubbles. Cool, stir and add vanilla. Pour into molds and put in the freezer for 3-4 hours.

Ice cream production business plan

Equipment and premises

Premises are required to accommodate production facilities with total area from 150m 2 , where lines for the production of ice cream and packaging, refrigeration equipment will be located.

This room should be electrified, and water supply and sewerage should be carried out in it. For transport - a convenient entrance.

We will purchase a production line with a capacity of 250 kilograms per shift, which consists of:

• component mixer - 350,000 rubles;
• filter - 25,000 rubles;
• oil melter (butter and coconut) - 195,000 rubles;
• homogenizer - 80,000 rubles;
• pasteurizer - 400,000 rubles;
• maturation containers final product- 400,000 rubles.
• shutoff valves - 200,000 rubles;
• pumps 3 pieces - 200,000 rubles;
• freezer - 900,000 rubles.

The total cost of such a line will cost 2,750,000 rubles.

In addition, it is necessary to purchase equipment for packaging the produced ice cream - 600,000 rubles.

And for storage - 1 refrigerator compartment for 110,000 rubles.

The total amount of capital costs is 3,460,000 rubles.

Working capital (costs of raw materials and their delivery) - 450,000 monthly.

The average monthly rent will be 30,000 rubles (360,000 rubles per year).

Utility bills - 10,000 rubles each month (for a year - 120,000 rubles).

Prepare a package of documents (for registration entrepreneurial activity or organization of an enterprise) - 50,000 rubles.

Total - 200,000 rubles.

Recruiting staff

Minimum number of staff 6 people:

• technologist - 30,000 rubles;
• production manager - 25,000 rubles;
• head of the sales department - 25,000 rubles;
• 2 workers - 15,000 rubles each;
• loader - 10,000 rubles.

The annual wage fund will be 1,440,000 rubles.

Let's calculate the annual profit

The average cost of 1 kilogram of ice cream is 250 rubles/kg.

Released products - 250 kg. x 22 working days = 5500 kg. x 250 rubles / kg = 1,375,000 rubles, and for the year, respectively - 16,500,000 rubles.

Gross annual profit (revenue-cost) - 11,100,000 rubles.

General expenses (capital + operating costs) - 1,920,000 rubles.

Profit before tax (gross profit - total expenses) = 9,180,000 rubles.

Profit after payment of a single tax (15%) - 7,803,000 rubles. This will be the net profit.

Profitability (net profit/revenue) will be 47.3%.

Sales of finished products

It is important not only to make ice cream, but also to be able to sell it. Due to the low cost, trade margin is sometimes more than 50%. Therefore, the ability to create a commodity-selling network practically guarantees impressive profits.

The most important thing is to choose the right point for implementation. Appetizing appearance is also important.

You can supply finished products through wholesalers or supermarket chains. Also a good option is to implement finished products through its own sales representative, who will personally cooperate not only with large stores, but also with small ones.

For students of universities and food-oriented technical schools, excursions can be arranged with a detailed visual demonstration of the entire hardware circuit.

To sell soft ice cream, you can put outlet in the most crowded place - park, supermarket, market, etc. The main advantage of such a product is wastelessness. After the end of the working day, the remaining ice cream can simply be drained into a bowl and put in the refrigerator. And in the morning - re-fill the mixture into the freezer, and in a few minutes start trading with renewed vigor.

Homemade ice cream can be supplied in bulk to cafes and restaurants. First you need to make a small trial batch and dilute it for testing at potential places of sale. Surely there will be more than one institution that wishes to conclude a supply contract with you.

Advertising will also help increase sales. In the absence of the required amount to create an advertising video, you can limit yourself to an ad in a local newspaper. Promotions and discounts at the very beginning of business activities will help the business quickly pay off and bring only positive results.

Introduction:

*Ice cream is a refreshing and nutritious product containing 25-42% solids. The digestibility of ice cream is 95-98%, the energy value of 100g is 419-1006 kJ, and in terms of calories it is not inferior to beef of the first category. Ice cream has a high nutritional value and is easily digested by the human body. This product contains milk fat, proteins, sugars, minerals, vitamins A, B, D, E. In addition, ice cream is a delicious, aromatic product that is always eaten with pleasure. With all the advantages of ice cream, the main thing in it is its unique taste, which is remembered from childhood and accompanies us all our lives.

1. The history of ice cream.

So many conflicting stories have been written about the origin of people's favorite delicacy - cold, sweet ice cream - that it is rather difficult to determine where the truth is and where the legends are.

Ice cream has been accompanying mankind for more than one millennium. The history of ice cream is very ancient and fascinating.

The first ice cream appeared not in ancient Greece or Rome, but in Ancient China 5 thousand years ago.

The Chinese enjoyed snow and ice mixed with slices of oranges, lemons and pomegranate seeds. Recipes and storage methods were kept secret and were declassified only in the 11th century BC in the book "Shi-king" - the canonical collection of ancient songs.

At the court of the Roman emperor Nero (1st century AD), cooling and sweetened juices were already widely used. It is noteworthy that snow for their preparation was delivered from remote alpine glaciers, and for long-term storage of snow, capacious ice cellars were built.

Ice cream was served to Alexander the Great during his campaigns in Persia and India. During a long siege of cities, a large amount of snow was mined from the mountains, in which berries and water were also frozen. In order to prevent the snow from melting, they organized special relay races of slaves. By the way, it was his soldiers who came up with the idea of ​​adding wine, honey and milk to water with fruits.

According to legend, the recipe for fruit ice cream (chilled sorbet) was brought to Europe by the Venetian traveler Marco Polo from China at the beginning of the 14th century. The recipes for making ice cream were classified for a long time, court cooks took a vow of silence about everything that was connected with its preparation.

History has brought us legends that among the admirers of ice cream was Napoleon Bonaparte himself. In the declining years of the former ruler of Europe, his admirers sent a device for making ice cream to St. Helena.

Under Napoleon III (1852 - 1870), ice cream in cups and sundaes were produced in Paris for the first time (the famous ice cream comes from the French city of Plobiere-Les-Baemes), in Italy - great lovers of mixing the most incredible products, came up with assorted ice cream with fruit, nuts, liquor, biscuit pieces and even flowers; in Austria, glace coffee and chocolate ice cream. At this time, frozen whipped cream mixed with finely chopped almonds and maraschino, puff ice cream with strawberries and grated dome-shaped chocolate appear. New varieties of ice cream prepared on the occasion of celebrations were quickly adopted in mass production.

Ice cream recipes arrived in America with English settlers when, in 1774, entrepreneur Philip Lenzi announced in New York newspapers that he had just arrived from London with a stock of recipes for various sweets, including such a rarity as ice cream.

In 1834, American John Perkin patented the idea of ​​using ether in a compressor apparatus. 10 years later, the Englishman Thomas Masters received a patent for an ice cream machine, which was a tin jug with a rotating three-blade spatula, surrounded by ice, snow, or a mixture of one of them with salt, ammonium salts, saltpeter, ammonium nitrates or calcium chloride. According to the patent description, Masters' machine could cool, as well as simultaneously freeze and whip ice cream. In Russia, in 1845, merchant Ivan Izler was granted a patent for an ice cream machine. In 1848 two ice cream machines were patented in the USA. One of them consisted of a device with two concentric cylinders, one of which was filled with refrigerant. In 1860, Ferdinand Carré created the world's first absorption refrigeration machine, powered by liquid and solid absorbent. Four years later, Carré improved the compression machine, in which for the first time a new refrigerant, ammonia, was used.

Serial production of freezers began in the second half of the 19th century by Jacob Fussell in Baltimore. A little later, refrigeration machines were invented, methods for producing and storing ice were developed, which made it possible to significantly reduce labor intensity, and, consequently, the cost of ice cream. And in 1904, in the city of St. Louis, an international ice cream exhibition was held, at which the first machine for the production of waffle cups was demonstrated.

In 1919, American Christian Nelson developed recipes for chocolate-glazed ice cream. It was called "Eskimo Pie" (Eskimo Pie). Nelson took his products around the cities and sold them while showing a film about the Eskimos. In the end, the word "share" fell out, and ice cream on a wooden stick began to be called simply popsicle.

Thus, the technique and technology of industrial production of ice cream has been constantly improved. In a number of countries, specialized firms began to be created for the production of machines and equipment for the production of ice cream, which has become a common attribute of urban cafes. But behind this common occurrence was rapid scientific progress in the study of cooling processes. It was he who made it possible to master the production of machines and equipment for the industrial production of ice cream.

2. Ice cream classification.

Ice cream is a product obtained by whipping and freezing a pasteurized mixture of cow's milk, cream, sugar, stabilizer and fillers. Due to the content of milk fat and proteins, carbohydrates, minerals and vitamins, it has a high value and is easily absorbed by the body.

Ice cream is divided into basic and amateur kinds . TO main include dairy, creamy, fruit and berry, aromatic ice cream and ice cream.

Milk, cream ice cream and ice cream are produced on a milk basis without fillers and with fillers (nuts, coffee, candied fruit).

Fruit and berry ice cream is made on a fruit and berry basis, it has the following composition: mass fraction of sugar - 27%, solids - 30%.

Aromatic ice cream is produced on the basis of sugar syrup with the addition of aromatic food essences, oils and colorants.

In production amateur species ice cream use more diverse combinations of raw materials. Amateur types include ice cream prepared on milk, fruit and berry bases.

Many recipes provide for the simultaneous use of dairy and vegetable raw materials. Whipped, that is, saturated with air bubbles, mixtures are frozen.

By way of production ice cream is divided into:

hardened

homemade

* Hardened ice cream is a product made under production conditions, which, after leaving the freezer, is frozen to low temperatures - (18 ° C and below) in order to increase storage stability. In this form, it is stored until implementation. Hardened ice cream has a high hardness.

* Soft ice cream is called, which is produced mainly in public catering establishments and is eaten immediately after leaving the freezer with a temperature of -5˚; -7˚С. It is creamy in texture and appearance.

*Homemade ice cream is made at home using a compress refrigerator.

Hardened ice cream is classified according to the type of product and filler, it is divided into basic and amateur types.

Ice cream of amateur types is produced in relatively smaller quantities than ice cream of the main types.

By type of packaging hardened ice cream is subdivided into weight - in cardboard boxes with liners made of polymer film, in sleeves; large-packed - in cardboard boxes, cakes, muffins; small-packed - tubes, in cups, briquettes.

Ice cream, depending on the mass fraction of fat, is divided into:

- low-fat dairy;

- dairy classic;

- milk fat;

- creamy classic;

- ice cream classic;

- fatty ice cream.

Ice cream, depending on the surface design, is divided on the:

- decorated;

- glazed, including popsicle;

- glazed decorated;

- in wafer products, including glazed and/or decorated in wafer products;

- in biscuits, including glazed and/or decorated biscuits.

2.1. Assorted ice cream.

On the basis of ice cream, such cocktails are prepared as: parfaits, ice creams, frappe, sandi.

parfaits - the highest quality creamy ice cream. In America, parfaits are prepared according to a special recipe, and the main ingredient is an egg. We have ice creams for parfaits.

ice creams - one of the varieties of ice cream-based cocktails. It is a nutritious fruit and berry drink. 1 scoop of ice cream is placed in the creamer, then the rest of the ingredients. These cocktails are served chilled but without ice. Served when served with a spoon and a straw. Ice cream with other ingredients is not mixed.

Sandy - This cocktail owes its appearance to the American state of Massachusetts. The basis of the sandy is ice cream, often diluted with syrups and decorated with fresh or canned fruits - peaches, pineapples or bananas. Sweet cherries, preferably yellow, as well as nuts poured with syrup, are also suitable for decorating a sandy. A few scoops of ice cream are placed in a bowl, then juice, syrup are poured, sprinkled with nuts or chocolate. Served with a spoon.

Frappe - a kind of cocktail, but only a thick consistency, the main part of which is ice cream, chilled milk, fruit and berry syrups or juices, whipped cream.

Assorted ice cream- By combining ice cream with drinks, you can prepare a highly nutritious dessert, very beautiful in appearance.

3.Methods and technologies.

What is ice cream in terms of physics?

Ice cream is frozen milk.

However, if you put milk in the freezer and freeze it, you end up with a piece of ice that doesn't look like ice cream at all. It turns out that it's all about the technology of making ice cream. At the ice cream factory, milk, specially prepared and cooled to the pour point, is fed to a device that sprays it inside freezer. In this case, many small crystals of milk are formed, which immediately freeze together (the temperature in the freezer is low). This resulting mass is our favorite ice cream. Small crystals of ice cream are very similar in structure to fine granulated sugar, or to fine-fine foam, and therefore represent, as it were, a continuous mass. Such systems, consisting of many particles of a substance distributed in a homogeneous medium, are called dispersed by physicists. The properties of a dispersed substance differ from the properties of those substances from which such a mass is formed. You can notice this yourself if you try ice cream and regular frozen milk - they will vary greatly in taste.

Can you make ice cream at home?

With some effort and patience, of course, it is possible. We offer a simple recipe for making ice cream at home. First, prepare the milk: for this we heat it and dissolve one or two tablespoons of granulated sugar in it. Let's wait until the milk has cooled down, and put it in the refrigerator - it is desirable to cool it to a temperature as close as possible to the freezing point of milk. Next, beat the chilled mass, preferably with a mixer, and quickly put it in the freezer for accelerated freezing. The frozen mass will taste like milk ice cream. And if you add the yolk of a chicken egg to it before whipping the milk mixture, you get ice cream ice cream.

(Source: based on the materials of the journal "Quantum" No. 3, 2000, author N. Eliseev)

3.1. Technologies past and present...

Nancy Johnson is a manual ice cream maker.

In 1843, an Englishwoman, Nancy Johnson, invented a hand-held ice cream maker and patented it. But she did not have enough money to organize the production of new equipment. The patent had to be sold to the Americans. And then in 1851 the first factory was opened in Baltimore and the first industrial batch of ice cream was produced. And for more than 150 years, the process of improving recipes and technologies has not stopped for a single day.

Jacob Fassel - commercial production.

In 1851, Jacob Fassel founded the first commercial ice cream factory in Baltimore. Alfred Krall patented the ice cream mold and spoon on February 1, 1897.

Mechanical freezing.

The treat became more easily distributed and more profitable with the introduction of mechanical freezing and the advent of ice cream shops. In 1926, Clarence Vogt invented the first successful commercial ice cream maker.

Tubes.

The first ice cream cone was made in America in 1904 at the St. Louis Fair.

Soft ice cream.

British scientists (whose group included a young Margaret Thatcher) came up with a method in which twice as much air is added to ice cream, and "soft" ice cream is obtained.

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Manufacturing.

To make ice cream, you must first make a mixture, and then process it. An ice cream mix is ​​a set of different components included in its composition in accordance with the recipes, which is specially processed and prepared for churning. The number of ingredients used to make ice cream is huge. Judge for yourself: these are, first of all, various dairy products (milk, cream, canned milk, butter), sugar, honey, other sweet foods, eggs, various fruits, berries and even some vegetables, fresh, canned and dried, obtained from them juices, syrups, extracts, flavoring and aromatic substances, food acids, dyes, etc.

The technological process of making ice cream consists of the following main operations:

mixing (first, the components are dissolved in the liquid part, then the mixture is filtered, prepared stabilizers are added to it and pasteurized; after pasteurization, the mixture is hot for homogenization; the homogenized mixture is cooled to a temperature of -2 ... -4 ° C and left for several hours for maturation);

milling - the main operation that forms the commercial properties of this product (they use special devices - milling cutters; during the milling of the mixture, two processes occur simultaneously: cooling and saturation with air; the product acquires a thick, creamy consistency, and its volume increases by 1.5-2.0 times due to air; the resulting “soft” ice cream is poured into molds and it goes to hardening);

hardening - it is necessary for the ice cream to acquire a solid consistency and the ability to be stored for a long time (ice cream is hardened in special cold generators; the temperature of the hardened product drops to -12..-15°C, the consistency becomes solid). Ice cream is ready, it remains only to wrap it.

In order for us to get the desired pleasure from ice cream, it is necessary to create a single cold chain all the way from the freezer to the buyer. At the same time, this chain (production workshop - trade base - store or tray - buyer) can stretch for several hundred kilometers if, for example, the product is transported to remote areas of the region. Low-temperature refrigerated counters and chambers, isothermal, equipped with refrigeration units, allow to deliver hardened ice cream to the consumer “intact” railway wagons and cars.

Before ice cream goes to the customer, it must be subjected to careful production control. The controllers will determine its organoleptic characteristics (taste, smell, consistency, color, structure), determine the content of fat, solids, sugar, acidity in it, examine microbiological indicators - that is, make sure that this batch of product meets the requirements of regulatory documentation. And only if all these indicators comply with the regulatory documentation, you and I will be able not only to see ice cream on the store counter, but also to taste it.

3.2. Quality assessment of ice cream.

When conducting an organoleptic evaluation of ice cream, it is important to identify the causes of defects in raw materials and finished products in order to prevent their occurrence in a timely manner, improve the quality of ice cream produced, and completely eliminate the production of non-standard products. In the process of organoleptic control, the taste and smell of raw materials for ice cream, semi-finished products and finished products entering the enterprise, as well as the structure and consistency, color, appearance, container condition and labeling of the finished product are evaluated.

When assessing the quality of ice cream internally, to characterize the implementation of the quality plan by individual teams, shifts, the enterprise as a whole uses a 100-point system, the indicators of which are as follows:

indicators
Taste and smell
Structure
Color and appearance
Package

Determination of overrun ice cream.

Soft ice cream.

Methods for determining the overrun of soft ice cream S is the same as the volume of the proportion of air in this product. The calculation is carried out according to the formula:

Hardened ice cream.

To establish the overrun of hardened ice cream, first determine the volume fraction of air in it according to the above method. Then the overrun is calculated.

To express the overrun of soft and hardened ice cream as a percentage, the results obtained must be multiplied by 100.

Determination of the mass fraction of dry matter and moisture in ice cream

The mass fraction of dry matter in ice cream is determined by the arbitration method (drying at 102 º -105 º C) and the express method (drying at 180 º C).

Arbitration method. In an oven with a temperature of 102 º -105 º C, a glass cup is placed for weighing with well-washed and calcined sand (20 - 30 g) and a glass rod that does not protrude beyond the edges of the cup. After 30 minutes, the cup is removed from the oven, closed with a lid, cooled in a desiccator and mixed to the nearest 0.001 g.

10 ml of the ice cream mixture is added to the glass with a pipette, closed with a lid and immediately weighed. The ice cream mixture is thoroughly mixed with sand with a glass rod. An open cup is heated in a water bath at a frequency of stirring the contents until a crumbling mass is obtained. Then the cup with the mixture is placed in an oven at a temperature of 102 º -105 º C. After 2 hours, it is removed, covered with a lid, cooled in a desiccator and weighed. Subsequent weighing is carried out after drying for 1 hour until the difference between two successive weighings reaches 0.004 g or less.

The mass fraction of moisture in the ice cream mixture M (in %) is calculated by the formula:

where a is the mass of a glass with sand, a glass rod and a mixture of ice cream before drying g; a 1 is the mass of a glass with sand, a glass rod and a portion of the ice cream mixture after drying, g; a a is the mass of a cup with sand and a glass rod g;

Discrepancies between parallel determinations should be no more than 0.2%. The mass fraction of dry matter C in ice cream in% is calculated by the formula C \u003d 100-M.

Express method. Pipette 1 ml into a weighed aluminum cup. ice cream mixtures and weighed on an analytical balance. Then add 1 ml. distilled water and gently rocking the cup, mix the contents, distributing it evenly over the bottom. A cup with a sample is transferred to a heating device, on which there is an iron sheet with a surface temperature of about 180 º C. Evaporation is carried out with intense boiling of the liquid, so the dry substance remains in the form of a porous mass. If the moisture evaporates slowly (without boiling), then the residue forms a dense film in the cup, which is difficult to dry. After all the moisture is released, the residue turns yellow.

The cup is transferred to an oven with a temperature of 110 º C for 10 minutes. After that, having closed the cup with a lid, it is cooled in a desiccator and weighed. According to a formula similar to that given in the description of the previous method, the mass fraction of moisture is calculated, and then the dry matter. Discrepancies between parallel determinations should not exceed 0.5%.

Ice cream production technology includes raw material preparation, mixture preparation, filtration, pasteurization, homogenization (for milk-based mixtures), cooling, storage, mixture freezing, packaging, hardening, and additional hardening of ice cream.

Technological operations:

1. Preparation of the mixture.

Ice cream mixtures are prepared in accordance with recipes, which are calculated based on the actual availability of raw materials and their composition. The calculation of ice cream mixture recipes consists in determining the mass of raw materials that provide the required composition of the mixture in terms of the mass fraction of fat, SOMO (dry skimmed milk residue), sucrose and others. constituent parts product.

The preparation of an ice cream mixture generally consists of the steps of preparing an aqueous phase and mixing the fat fraction and solids of the mixture in a flow or batch process. For mixing raw materials in the preparation of mixtures for ice cream, universal heat-exchange tanks are used. The water phase of the ice cream-milk mixture and/or water is preheated to a temperature of 40-45°C using plate heaters. For the production of solids and fats, devices such as dispersers are used. Depending on the performance of the mixture preparation area, appropriate equipment is used to automate and simplify the process: screw lifts, oil melters.

2. Filtering.

After preparation, the mixture is filtered. Typically, two-section capacitive filters are used. This operation is necessary to remove from the mixture of undissolved lumps of raw materials (powdered milk, stabilizers, etc.) and possible various mechanical impurities also after pasteurization. The filter media in the filters are periodically cleaned and replaced to prevent large amounts of sediment from accumulating.

When using continuous pasteurizers, the mixture is filtered after mixing the components.

In the case of using devices of periodic action simultaneously for mixing components and pasteurization, the mixture is filtered only after pasteurization.

3. Pasteurization.

The increased content of solids in the mixture increases its viscosity and has a protective effect on microorganisms. In this regard, more stringent regimes for the heat treatment of the mixture have been established. Long-term pasteurization of ice cream mixtures occurs at a temperature of 68 ° C with a holding time of 30 minutes, short-term pasteurization at 75 ° C with a holding time of 20 minutes and high-temperature pasteurization at 85--90° C with a holding time of 50 seconds. Before pasteurization, the mixture is pumped to the filter, where mechanical impurities and undissolved particles of the components are separated from it. The filtered mixture with a temperature of at least 45 ° C enters the pasteurizer.

4. Homogenization.

Homogenization of the mixture significantly improves the quality of ice cream and facilitates further processing. In a homogenized mixture, the viscosity increases sharply, depending on its fat content, it increases by 5-15 times. In this regard, during maturation or storage in the mixture there is no settling of fat, which facilitates its further processing. In the process of whipping, a mixture with increased viscosity and the presence of a large number of small fat globules absorbs air more easily, and during hardening, the formation of large ice crystals is prevented. As a result, a more plastic ice cream is obtained from a homogenized mixture, with a delicate homogeneous structure, with a pronounced taste of milk fat, which, moreover, is more easily absorbed by the body.

The homogenization temperature of the mixture must be at least 63 °C. Lower homogenization temperatures cause fat globules to form in the mixture. During whipping, these accumulations of fat globules destroy air bubbles and impair overrun of ice cream. The result is a product of a coarser consistency and with noticeable grains of fat. In this regard, it is necessary to immediately send the pasteurized mixture to the homogenizer, preventing its temperature from dropping.

It has been established that the pressure during the homogenization of ice cream mixtures is inversely related to their fat content. Taking this into account, mixtures for milk ice cream are homogenized at a pressure of 12.5–15 MPa, mixtures for creamy ice cream? at 10-12.5 MPa, mixtures for ice-cream - at 7.5-9 MPa. Mixes for fruit and berry and aromatic ice cream do not require homogenization.

5. Cooling the mixture.

The purpose of cooling the ice cream mixture is to prepare it for ripening, as well as to create unfavorable conditions for the development of microorganisms during its storage. After homogenization, the mixture is cooled to t = 2–60°C. For this purpose, plate pasteurization-cooling units, plate and shell-and-tube coolers, VDP, cream-ripening baths, etc. are used. °C.

6. Ripening.

The mixture is sent to tanks or cream-ripening baths, where it is stored at a temperature of 4-6 ° C for no more than 24 hours, at a temperature of 0-4 ° C for no more than 48 hours. Storage is an obligatory stage of the technological process only for ice cream mixtures prepared using gelatin (stabilizer). Such mixtures must be kept at a temperature not exceeding 6 ° C, 4-12 hours. With slow stirring, so that all elements are evenly distributed, emulsified and developed the ability to incorporate air.

During the maturation of the mixture, approximately 50% of the milk fat hardens due to the crystallization of some glycerides. Milk proteins and the stabilizer swell during aging, absorbing moisture, some components of the mixture are adsorbed on the surface of the fat globules. As a result, the viscosity of the matured mixture increases, and the amount of free water decreases, which prevents the formation of large ice crystals during the freezing of the mixture. The ripened mixture absorbs and retains air more intensively during freezing, which improves its overrun and provides a delicate structure of ice cream.

The maturation time depends on the hydrophilic properties of the stabilizer used. When gelatin is added to the mixture, the maturation process lasts at least 4 hours. The use of agar and agaroid, which have high hydrophilicity, excludes the maturation process. In this case, immediately after cooling, the mixture can be sent for freezing. If for some reason the cooled and ripened mixture cannot be sent for further processing, it can be stored in isothermal containers at a temperature of 2-6 °C for 24 hours.

7. Freezing.

This operation is the main one in the production of ice cream, during which the mixture turns into a creamy, partially frozen and expanding mass. In a chilled mixture, from 1/3 to 1/2 of all water is in a free, unbound form. During the freezing process, it is this water that freezes and turns into small ice crystals. Depending on the type of ice cream produced and the freezing temperature, 29-67% of all free water is frozen. The consistency of ice cream also largely depends on the size of the resulting ice crystals, which should not exceed 100 microns. With proper freezing of moisture, the product acquires a fairly dense creamy structure, without noticeable ice crystals.

During freezing, the ice cream is saturated with air, which is evenly distributed throughout the mass in the form of bubbles with a diameter of not more than 60 microns. As a result of saturation with air, the volume of the frozen mixture increases by 1.5-2 times.

The most advanced equipment for freezing the mixture are continuous freezers, in which the process takes place instantly and the resulting product is of high quality.

The supply of mixture and air into the freezer and the unloading of ice cream are carried out forcibly, under pressure. Therefore, in a frozen mixture under a pressure of 0.5–0.8 MPa, air bubbles are in a compressed state. When leaving the freezer, getting into conditions of normal pressure, air bubbles increase in volume, which, in turn, increases the volume of ice cream, that is, increases its overrun. The frozen mixture leaves the freezer with a temperature of minus 3 to minus 5 °C and overrun reaching 100%.

Reducing the overrun of ice cream sharply reduces its quality, the product acquires a dense texture with a rough structure. If overrun is too high, a snow-like consistency appears, which also reduces the quality of the product. For ice cream produced on a milk basis, overrun is recommended 70-100%, for fruit and berry and aromatic types? 35-40%. Overrun is determined by weight or volumetric method.

8. Hardening.

To give ice cream more strength, it is subjected to hardening. This process is longer than freezing.

In the process of hardening, new ice crystals are formed and they coalesce into a rigid crystallization framework. As a result, ice cream acquires a dense texture and high strength. During hardening, the total amount of frozen free water in ice cream reaches 90%, and the temperature in the thickness of a portion of well-hardened ice cream ranges from minus 10 to minus 18 °C. In the remaining small amount of water, the concentration of sugar and salts increases greatly; to freeze such solutions, a temperature of minus 50 to minus 55 °C is required.

The duration of hardening affects the quality of the finished product. Freezing water quickly will form small ice crystals in the ice cream, and it will have a softer texture. You can significantly reduce the duration of ice cream hardening by using forced air circulation in the chamber. If at natural circulation air in the chamber with a temperature of minus 22 ° C, the hardening of ice cream in the sleeves lasts at least 24 hours, then with increased air circulation, the speed of which is 3-4 m / s, it is reduced to 10-12 hours.

9. Packaging and storage of ice cream.

The container used for packaging, storage and transportation of ice cream is divided into consumer and transport containers. Consumer packaging is a one-time use container. It includes labels and bags for wrapping small-packed ice cream, as well as paper cups and boxes in which portions of ice cream are placed. The material used for packaging should be completely harmless to the human body and should not impart extraneous flavors and odors to ice cream during prolonged contact. For better preservation of the product, it is necessary that it be waterproof and moisture-resistant, grease-proof and fat-resistant, have low gas, vapor and aroma permeability and good frost resistance.

Labels and sachets are made from parchment, subparchment, lacquered cellophane, backed foil and laminated paper. Cups - made of paper and cardboard with a waterproof food coating or polystyrene. Ice cream boxes with a capacity of 0.25 kg are made of cardboard white color with a waterproof coating or laminated foil.

In a transport container, the product enters the distribution network. Small-packed ice cream, boxes with cakes and large-packed ice cream weighing 0.5--2 kg are placed in corrugated cardboard boxes. You can use boxes made of boxed cardboard. For the delivery of small-packed ice cream, double-shift isothermal containers with insulation, with a capacity of 20–25 kg, are also used.

Isothermal containers and sleeves are reusable containers.

Before sending ice cream to public catering enterprises and to the distribution network, it is stored in chambers with an air temperature not higher than minus 18 ° C and a relative humidity of 35--90%. The camera must maintain strict sanitary regime.