DISSERTATION REPORT

PACKAGING OF ICE-CREAM
As on

23th October, 2012

Submitted by: - ROHIT D GHULE

Intensive Training Course Batch- 46th Year 2012-13

ACKNOWLEDGEMENT

I would like to express my gratitude towards my teachers who have helped me throughout the completion of the dissertation. The ultimate objective of this dissertation is to learn new concepts and apply them in an innovative manner. I have put in my best while working on this project and it is my pleasure to present the dissertation report on PACKAGING OF ICE CREAM. I express true sense of gratitude towards the

Head of Department, Mrs. Jyoti Baliga and my dissertation guide, Mr. T.M. Mallik for their invaluable guidance and help. I would also like to express my appreciation and thanks to all my friends who knowingly and unknowingly have assisted me throughout my hard work.

ROHIT D GHULE

CONTENTS 1. OBJECTIVES 2. INTRODUCTION 3. PACKAGING OF ICE CREAM AND FROZED DESSERTS 4. HARDENING AND STORAGE 5. TRANSPORTATION OF FROZEN DESSERTS 6. SENSORYATTRIBUTES 7. COMMON DEFECTS AND THEIR REMEDY 8. CONCLUSION 9. APPENDIX

1) OBJECTIVES

Types of packaging materials used in packaging of ice-cream Importance of hardening of ice-cream and the method Methods of transportation of ice-cream and frozen desserts Desired sensory attributes of good quality ice-cream Defects occurring in ice cream, their causes and remedies

2) INTRODUCTION
In the earlier unit we studied how the ice cream mix, properly pasteurized, homogenized and aged, is frozen in an ice cream freezer. Freezing process in the ice cream freezer involves conversion of part of water of ice cream mix into smaller ice crystals with simultaneous incorporation of air in the mix to increase the volume (over run) of ice cream. The partially frozen ice cream is then quickly drawn from the freezer, filled in suitable containers and transferred to a very low temperature room for freezing of remaining water portion of ice cream. After ice cream has been sufficiently hardened it is ready for consumption. Until it is sold to customer, ice cream should be properly handled such that the quality of ice cream is not affected in any way. This can be achieved by maintaining cold temperature conditions during handling, storage and transportation of ice cream. Good quality ice cream can only be made by selection of good quality ingredients and maintaining standard processing conditions a various stages of manufacture. Quality of ice cream should be evaluated routinely by organoleptic tests by comparing with approved or accepted score card for this purpose. If any defects are noticed in ice cream the reasons for their occurrence should be identified and suitable measures be taken to remove the defects.

3) PACKAGING OF ICE CREAM AND FROZED DESSERTS

Generally packaging of ice cream is done before hardening. In few cases it is done after hardening. When ice cream is drawn from the freezer, it is usually collected in containers, which give it the desired shape or size for convenient handling during hardening, storage and marketing The important requirements of packages for ice cream are: Protection against contamination Attractiveness Ease of opening and re-closure Ease of disposal

Desirable requirements of packages are: Protection against moisture Protection against temperature fluctuations

Ice cream packages are of two types: i) Multi- service: These types of packages are in limited use only. Tinned steel cans or stainless steel cans of different sizes and shapes are used. These cans are cleaned, sanitized and used repeatedly.

ii) Single-service: These types of packages are now more popular and are available for both bulk sale and retail sale. As the name suggests these packages are used and discarded after use. Ice cream for bulk sale is packaged in containers with capacities ranging from 5 to 25 liters or more. Ice cream in this type of containers is distributed for sale of dipped ice cream especially in ice cream parlors, hotels etc. Ice cream is packaged in fibre-board cartons coated with wax or provided with plastic liners. All plastic cylindrical containers with re-closable lids are also now available for bulk packaging especially for carry home packages. For retail sale, ice cream is filled in small cups or cartons. The cups may be made out of paper or cardboard treated with wax or plastic. Plastic cups of various sizes and shapes with lids are also available for packaging of ice cream. In many of the ice cream factories the present trend is to make bricks of varying sizes. The bricks are made from the moulds into which ice cream has been filled after leaving the freezer and then hardened. The solid block of ice cream is first cut in smaller size and then wrapped in parchment paper or plastic film. This method of packaging is rapidly increasing in popularity. In view of large number of paper wrapped ice cream bricks sold in market, the hygienic quality of wrapping paper assumes considerable importance. It is essential to use only the best quality of paper for the purpose. Other ice cream and frozen desserts, which are first hardened and then packagedinclude chocolate coated ice cream in sticks, ice cream sandwiches, popcicles, water ices in sticks etc. These are first filled in moulds after freezing and then hardened. The hardened materials are removed from moulds and wrapped in suitable packaging materials.

4) HARDENINGAND STORAGE
Hardening is a continuation of freezing process. Only part of water in ice cream mix is converted into small ice crystals in the ice cream freezer. When ice cream is removed from freezer and put in the packaging materials it has a semi fluid consistency not stiff enough to hold its shape. Therefore freezing process is continued without agitation in a very low temperature room until the temperature of ice cream reaches 18 C or below, preferably 30C. This process is called hardening of ice cream. The refrigerated place where the hardening takes place is called hardening room or hardening chamber or cabinet. Quick freezing of ice cream during hardening is also desirable. Slow hardening will favour large ice crystals formation in ice cream and hence the texture of ice cream will be coarse. Time required to complete hardening process depends on the following factors: Initial composition of mix Temperature of ice cream drawn from freezer Over run in ice cream Size and shape of packages Temperature of air in hardening room Rate of air circulation in hardening room Sections of the hardening room where the ice cream containers are stored.

Hardening time of 6- 8 hr may be considered normal for the operation to be completed. However large containers may take more time as compared to small packages. i. Hardening Methods: The following hardening methods are used for fast hardening of ice cream: a) Hardening room: This is a low temperature cold store maintained at 30 C or lower with large storing space. Also a good air circulation is maintained throughout the room for uniform cooling effect. b) Hardening tunnel: This is a hardening room constructed in the form of an insulated tunnel through which large volume of air is discharged. The air circulated in the tunnel may be at 35 to 40 C and this helps in fast hardening of ice cream. Small blast tunnel hardeners may also be located in hardening room for faster hardening. Manufacturers of large volume of ice cream prefer to have this type of system. c) Hardening cabinet: This is a small, refrigerated cabinet maintained at 25 C or below. It may have two or more compartments separated from each other. Ice cream cups are tightly packed and stored in these compartments. This unit serves as hardening and storing cabinet. This type of unit is useful where volume of operation is low. d) Storage: After ice cream is hardened it is ready for sale. Until such time it is marketed ice cream should be stored at temperature at which it is hardened.

Hardening rooms or cabinet can be used as storage rooms for ice cream. If separate storage room is used the following precautions should be taken: a) b) c) d) Room temperature should be maintained uniformly (-11 to 15 C) Ice cream packages should be piled very closely Cold air should be circulated uniformly throughout the room Frequent opening and closing of the room should be avoided.

5) TRANSPORTATION OF FROZEN DESSERTS

When ice cream is ready for sale it is usually transported under refrigeration. The temperature should not be allowed to rise as it causes ice cream to melt. Fine textural quality of ice cream will be lost if the ice cream is allowed to melt and freeze again in the retailers cabinet. Adequate precautions should be taken while transporting the ice cream to maintain low temperature. When it reaches the retailing point the temperature of ice cream should be the same as is maintained in the retailers cabinet. The following methods are used for transportation of ice cream: i) Refrigerated trucks: Insulated trucks fitted with mechanical refrigeration systems are available for transportation of ice cream and other frozen desserts. These are like refrigerated storage rooms built on trucks bodies. The refrigeration unit is operated by the power generated by the truck engine or by separate generators fitted to the truck. Similar arrangements are also available on rail wagons. The refrigerated trucks or rail wagons are used for transportation of large volume to long distances. Ice cream is loaded directly from the hardening room/ storage room into these refrigerated trucks for various distribution points. Temperature inside the refrigerated trucks is maintained by automatic controls provided in the refrigeration system. Frozen brine: The freezing temperature of water is 0 C. If some substances like salts are added to water the freezing point of solution will be lowered. The solution will not freeze at 0 C but at a lower temperature depending upon the amount of salt added to water. The freezing point of the salt solution becomes lower as more salt is added until a certain limit is reached. The temperature at which freezing point of the salt solution is not lowered by the further addition of salt is known as eutectic temperature. Calcium chloride solution of different concentration is used for preparation of frozen brine. Calcium chloride solution (brine) of specific gravity of 1.1 is filled in specially made jacketed metal containers known as eutectic pads. These pads are stored in low temperature refrigerated rooms or very low temperature brine tanks (-30 C or below). The containers attain a temperature of 21 C and are then removed and placed around the packaged ice cream in insulated container for transportation. Eutectic pads may be fitted into trucks and vans where mechanical refrigeration system is not provide. This system of having eutectic pads for keeping low temperatures during transportation of ice cream can be used for shorter distances or for shorter duration. Common salt mixed with plain ice is used in push-carts for keeping low temperature for sale of ice cream. iii) Dry ice: Dry ice is solid carbon dioxide with a freezing point of 78 C. Small pieces of dry ice wrapped in paper are placed around the package of ice cream inside an insulated container. If ice cream is properly packed with sufficient dry ice it will maintain low temperature over longer period and this system of shipping is useful for long distance transport also. But there are some advantages as well as disadvantages of using dry ice.

ii)

Advantages: Dry ice sublimes or passes directly to the vapour state. Hence there is no moisture and water-logging in the insulation of the storage space. It is light in weight. Packaging with dry ice is easy and Gives neat appearance. Disadvantages: It is expensive Availability is also limited

It should be handled with care as it may cause burns to the person who is handling because of extremely low temperature The ice cream must be un-packed or removed from dry ice sufficiently in advance to allow it to become softer so that it can easily be eaten.

6) SENSORYATTRIBUTES
Sense of taste and odour is important in judging the quality of any product. The properties analyzed by these two senses along with the sense of touch largely determine the consumers acceptability of the product. Consumers of ice cream are generally interested in the healthfulness and the organoleptic properties of ice cream as determined by senses of taste, odour and touch. Any change in the organoleptic properties will affect the consumer acceptability. It is therefore important to evaluate and judge the quality of ice cream regularly to maintain the acceptable quality of the product. Good quality ice cream should have the following properties: An attractive package Pleasant flavour Smooth uniform body and texture Melted ice cream should look like original ice cream mix Uniform natural colour Low microbial count

i. Judging of Ice Cream There are various methods available for evaluating the sensory characteristics of different dairy products.Anumerical scoring system is available by which it is possible to characterize the various attributes quality of product and assign a numerical score that reflects both the seriousness of the defect and its intensity.Asimplest scale would be from 1 to 10 where 10 would be assigned to the product which is without any defect and 1 would represent a very poor quality product. American Dairy Science Association (ADSA) has developed score -cards for judging dairy products including ice cream. The score-card actually has 100 points assigned to different characteristics depending on the product such as flavour, body and texture, appearance and colour, bacterial counts and container. The score card suggested for ice cream is given in Table 1.0. Table 1.0 Score card for Ice cream
Attributes Flavour Body and Texture Colour and Apperance (Package) Melting quality Bacteria Perfect score 45 30 05 05 15

ii. Procedure of Examination: i) ii) Sampling: At random sample is taken from the ice cream storage. Tempering of ice cream: For judging of ice cream a temperature of 15 to

12 C is satisfactory. Therefore, before judging the ice cream sample is kept in a dispensing cabinet for several hours before judging. iii) Sequence of observations: The following sequence is followed during judging of product: a) Note the type and condition of container and presence of any package defects b) Observe the colour of ice cream, its intensity and uniformity and whether colour matches its flavour c) While using a dipper for sampling, note the manner in which the product cuts, the evenness of cutting, the resistance offered during cutting, the presence of ice particles, whether the ice cream is heavy or soggy, light or fluffy. Set aside a sample in a petri-dish for observing the melting characteristics. iv) v) Take a small spoonful of ice cream and taste it. Quickly manipulate the sample between teeth and tongue and note the body and texture and flavour characteristics. Observe whether the melted ice cream in petri-dish is creamy, curdled, foamy or watery. the

vi) Send the sample for determination of bacterial count in the laboratory

7) COMMON DEFECTS AND THEIR REMEDY

Defects may appear in ice cream due to following reasons: Use of low quality ingredients Improper mixing of ingredients Faulty method of manufacture Faulty method of storage and transport

Quality of ice cream is judged for its delicate and pleasing flavour, smooth body and texture and attractive colour. The reasons for the development of defects in ice cream and the preventive actions to be taken to remove the defects are discussed in the following paragraphs. a) Colour and appearance Defects and Preventive Measures: i) Un-natural colour in ice cream develop due to following reasons: ii) iii) Careless-ness in adding colour Improper use of colour Use of foreign materials

Uneven colour results if the colour is not added and mixed properly. Excessive colour is due to addition of too much colour.

To avoid any of the above colour defects in ice cream correct amount of colour should be calculated, added and mixed thoroughly. Also the added colour should reflect the flavour characteristic of the ice cream. Cleanliness and neatness of the pakages should also be carefully observed. b) Melting quality defects and Preventive Measures i) Curdy melt down or curdled melt down: It indicates high acidity in the ice cream mix or the effect of any other factor which causes instability of milk proteins. This defect makes the consumer feel that inferior quality materials were used in the preparation of ice cream. The defect may be corrected by: ii) Using fresh dairy products Avoiding use of any product that might disturb natural salt balance of the mix Avoiding freezing of high acid mixes

Ice cream does not melt: Ice cream shows resistance to melting, retains shape when warmed and takes longer time to melt. The cause and remedial measures of the defect are discussed under soggy body defecs. Slow meltdown: It indicates use of excessive stabilizer (over stabilization) or faulty processing

iii)

of the mix. This condition may be corrected by taking the following measures: iv) Reducing amount of stabilizer Using fresh dairy products Homogenizing the mix at proper temperature and pressure

Whey leakage: When ice cream melts separation of whey occurs. This defect may occur due to poor qualityof ice cream mix or improper balancing of mix. This defect can be corrected by: Using good quality dairy products Balancing the constituents carefully Using better quality stabilizer

v)

Foamy meltdown: This is caused by incorporation of too much air in the ice cream during freezing (excessive over run). Hence the defect may be corrected by reducing the over run and reducing the amount of emulsifier or egg products.

c) Body and texture defects and Preventive Measures The body of ice cream refers to firmness and consistency while texture refers to the fineness of the product, which is dependent upon the number, size, shape and arrangement of ice crystals and other particles. The ideal body of ice cream is that which is produced by the correct proportion of milk solids together with proper over run and which melts fairly rapidly at room temperature to a smooth liquid similar in consistency and appearance to sweet cream containing about 40 % fat. i) Crumbly body: It is a condition in which ice cream does not hold together properly. It lacks cohesion or breaks apart very easily. It is associated with low total solids content, insufficient stabilization, excessive over run, imperfect homogenization and large air cells. This defect can be remedied by: ii) Increasing the total solids content Increasing the stabilizer Decreasing the over run Soggy body: Ice cream with a dense body and wet appearance is an indication of soggy body. It is due to a low over run, high concentration of sugar that lowers the freezing point, excessive use of stabilizer or delayed packaging of ice cream after freezing. This defect is also similar to other defects such as gummy, doughy, sticky, pasty and gluey. Excessive stabilization or high total solids content produce a chewy or gummy body while certain types of gums and syrups cause pasty or sticky body. Soggy body and other related defects contribute to high melting resistance. These defects can be corrected by: Maintaining correct over run Reducing the quantity of stabilizer Use of a combination of stabilizers Reducing the sugar content

iii)

Weak body: Ice cream lacks firmness or chewiness and is invariably accompanied by rapid melting. This defect is due to low total solids content combined with insufficient stabilization. This defect can be corrected by: increasing the total solids content adding correct amount of stabilizer properly ageing the mix

d) Texture of ice cream: Ice cream having an ideal texture will be very smooth, i.e., the solid particles too small to detect in mouth. e) Buttery texture: This defect appears in ice cream when lumps of butter- fat are detected easily in the mouth. This defect is due to high fat content, inadequate homogenization, mix entering the freezer at a higher temperature and partial churning of cream due to slow freezing. This defect may be corrected by: homogenizing the mix properly ageing the mix properly freezing the mix quickly

f) Coarse or icy texture: When the ice crystals are large or not uniform in size or that the air cells are too large in ice cream, icy texture is indicated. This defect is most commonly noticed in retailers shop. Large ice crystal formation in ice cream may be due to Insufficient stabilizer slow freezing in the freezer slow freezing in the hardening room insufficient ageing of mix

Formation of large air cells may be due to: Type of freezer used Use of mix of low whipping ability

Sometimes small ice particles are found in ice cream. These ice particles are formed when water droplets get into ice cream. This defect may be eliminated by Increasing total solids in the ice cream Increasing or adding correct amount of stabilizer Freezing quickly and drawing ice cream at a lower temperature from freezer Hardening ice cream quickly Reducing storage period Avoiding frequent heat shocks to ice cream

g) Fluffy texture: This defect is due to presence of large amount of air cells. It is due to incorporation of an excessive amount of air either as large or small air cells. This defect may be expected when the total solids content in ice cream is not more than one third of over run. When the air cells are large and the amount of air is excessive the texture is sometimes described as snowy or flaky. This defect may be removed by Decreasing over run Increasing total solids Decreasing the amount of emulsifiers

h) Sandy texture: This defect is easily detected by the presence of rough sand like particles in mouth when ice cream is tasted. This defect may be due to presence of more non-fat milk solids, which contribute more lactose. Higher amount of sugar may also lead to lactose crystallization. This defect can be eliminated by Reducing milk solids not fat content Replacing part of cane sugar with other sweetening agents like dextrose, corn syrup etc Maintaining uniformly low temperature during hardening and storage.

i) Flavour Defects and Preventive Measures: Ice cream flavour is essentially a blend of flavours from different ingredients used in its preparation. The dairy products and flavouring materials used have profound effect on the delicate flavour characteristics of ice cream.Any defect in these materials will therefore influence significantly the flavour of ice cream. Defects due to flavouring materials: i) High flavour: Excess of flavouring material will impart a sharp bitter flavour in ice cream. Poor quality flavouring material also imparts bitter flavour. This can be corrected by checking the quality of flavouring materials and adding correct amount to get the desired delicate flavour. Low flavour: It is due to insufficient amount of flavouring material. It requires addition of correct amount of flavouring material to overcome the defect. Harsh flavour: It is due to use of inferior flavouring substances. These substances or artificial extracts lack fine flavour . Also use of excess flavour cause this defect. Therefore correct quantity of superior flavours should be used. Acid flavour: This is caused by the presence of excessive amount of lactic acid. This can be corrected by: v) Using fresh dairy products Prompt and efficient cooling of mix Avoiding prolonged storage of the mix at high storage temperature.

ii) iii)

iv)

Bitter flavour: This defect may be caused by the use of inferior quality ingredients. The defect may be controlled by: Using good / fresh extracts Avoiding use of dairy products stored for long time at low temperature as certain type of

bacteria produce bitter flavour under these conditions. vi) Cooked flavour: This is caused by over heating the mix or using over heated concentrated dairy products. The defect can be prevented by: vii) viii) Carefully controlling pasteurization temperature Using concentrated dairy products without cooked flavour

Flat flavour: This results from the use of insufficient flavours, sugars or milk solids. By adding required quantities of various ingredients this defect can be corrected. Un-natural flavour: This is indicated by the flavour not typical of ice cream. The defect can be controlled by using good quality dairy products and flavouring materials. Synthetic flavours that are not correct imitation of true flavours are also considered un-natural. Similarly flavours due to poor gelation, fermented syrups, over-ripe or under-ripe fruits and rancid nuts are un-natural. Therefore use of such ingredients should be avoided to control this defect. Oxidized flavour: This defect is also known as tallowy or cardboard flavour and results from use of old or stored dairy ingredients especially fat rich products. This defect can be remedied by use of fresh dairy products and pasteurizing the mix at slightly higher temperature than recommended. Shrinkage: Besides flavour and body texture defects one another defect is also noticed in ice cream, especially in retail shops. Sometimes when well-filled packages are hardened and stored, the volume of ice cream shrinks leaving space either at the top or on the sides of the package. Cups then do not appear full. This defect is known as Shrinkage defect. The main reason for this defect to occur appears to be excessive over run in ice cream and too much fluctuation in storage temperature. Maintaining constant temperature during storage and avoiding rough handling during transportation will prevent this defect to a greater extent in ice cream.

ix)

x)

8) CONCLUSION
Ice cream is usually drawn from the freezer in containers, which give it the desired shape or size for convenient handling during hardening. It is then transferred to a very low temperature room and stored until it is sold to the consumers. Thus, ice cream is generally packaged before hardening except for soft serve ice cream. The packaging material for ice cream should protect it against contamination, should be attractive, easy to open and reclose, easy to dispose apart from providing protection against moisture loss or gain and temperature fluctuations. However, care should be taken to maintain deep freezer temperature during hardening, storage, transportation and marketing so that the quality of ice cream is maintained till it reaches the consumer. In general, ice cream should have a uniform body & texture, pleasant flavor, uniform colour distribution, optimum hardness and meltability, no bigger ice crystals formation, no sediments and optimum overrun. Use of low quality ingredients, improper mixing of ingredients, failure to formulate a balanced mix, faulty method of manufacture, improper packaging and faulty method of storage and transport, failure to maintain optimum cold chain etc., lead to the production of ice cream with defects. The common colour and appearance defects are un-natural colour, uneven colour and excessive colour. Flavor defects may be high flavor, low flavor, harsh flavor, acid flavor, bitter flavor, cooked flavor, flat flavor, unnatural flavor and oxidized flavor. Body & texture defects include crumbly body, soggy body, weak body, buttery texture, fluffy texture, sandy texture, shrinkage and melting defects like curdy melt down or curdled melt down, whey leakage, foamy meltdown in ice cream does not melt.

9) APPENDIX
Hardening Dry ice Foamy meltdown Crumbly body Soggy body : is a continuation of freezing process without agitation in a very low temperature room until the temperature of ice cream reaches 18C to 26C. : is solid carbon dioxide with a freezing point of 78C and is used for transportation of ice cream. : is a metl down defect in ice cream due to excessive over run caused due to high incorporation of air during freezing. : is a condition in which ice cream does not hold together properly, lacks cohesion or breaks apart very easily due to low total solids content. : is a condition wherein the ice cream will exhibit a dense body and wet appearance due to a low over run, high concentration of sugar, and excessive use of stabilizer or delayed packaging of ice cream after freezing.

Coarse or icy texture : is a texture defect, where large or irregular sizes of ice crystals or too large air cells appear in ice cream. Sandy texture : is a texture defect, wherein rough sand like particles is felt in mouth when ice cream is tasted due to presence of high level of non- fat milk solids and large size lactose crystals. : is a condition, wherein volume of ice cream shrinks leaving space either at the top or on the sides of the package when properly filled packages are hardened and stored.

Shrinkage

10) REFERENCES
Books:
Outlines of dairy technology Sukumar De Oxford University press, Delhi Ice cream W.S. Arbucle The AVI publishing company, Inc. Westport Connecticut United States Of America

Online: Wikipedia