PRODUCTION MANAGEMENT

PROJECT REPORT

ON

INDUSTRIAL VISIT

TO

JAMAAI ICE CREAM FACTORY

DONE BY,

KAVYA M M

RAJESWARI S

SUBHASHREE C

SONI KUMARI P
 INTRODUCTION
Jamaai ice cream is the industry where different flavors
are manufactured. Jamaai ice cream is the firm chiefly leading with
processing of ice cream. But also makes other products.

Jamaai ice cream produces different types of flavors of

ice cream for the people. Jamaai ice cream produces more of those
flavors, which are in demand in the market.

Jamaai ice cream is one of the famous ice cream

producing firms in Tamil Nadu. As of today, ice cream market has been
more competitive due to many new entries in the field but Jamaai ice
cream is holding its position and command in the market.

Jamaai ice cream was founded in 2004 by Saravana

Stores Group.
 LOCATION
Jamaai ice cream factory is located in padapai. This
factory is situated in sub -urban area which offers the factory with
many advantages like easy access to transportation, communication,
procurement of required raw material and a ready market.

ADDRESS:

Saravana Stores Foods Pvt.Ltd,

No 90, Wallajah road,

Padapai, Chennai 601301.

 Production department
It’s a combination of certain steps to obtain the final products
many processes are undertaken in creaming before the milk and the
milk products reach in the hands of the final consumer.

Jamaai ice cream factory has departments like quality control

department, purchasing department, production department, research
and development department, marketing department and packaging
department.
 RAW MATERIAL
 Milk can be considered as one of the main raw material for
producing an ice cream. Milk is procured from milk vendors. They
are measured from which a sample is drawn for testing quality.
 The next ingredient for producing an ice cream is sugar. Company
purchases them in bulk.
 Special attention is given to dry fruits. They are purchased,
cleaned and are cut before they are used.
 Butter and water are also used for producing ice cream.
 Essence and flavor which are permitted by government are used
to give flavor to ice cream. The factory differentiate the flavor by
naming C1, C2 & C3
Example: vanilla, strawberry, chocolate flavor etc.
 PRODUCTION PROCESS

Blending the mixture

The milk arrives at the ice cream plant in refrigerated tanker trucks
from dairy farms. The milk is then pumped into storage silos. Pipes
bring the milk in pre-measured amounts to stainless steel blenders.
Premeasured amounts of eggs, sugar, and additives are blended with
the milk for six to eight minutes.

Pasteurizing

The blended mixture is piped to the pasteurizing machine, which is

composed of a series of thin stainless steel plates. Hot water flows on
one side of the plates. The cold milk mixture is piped through on the
other side. The water warms the mixture to a temperature of 180°F,
effectively killing any existing bacteria.

Homogenizing

By the application of intensive air pressure, the hot mixture is forced

through a small opening into the homogenizer. This breaks down the
fat particles and prevents them from separating from the rest of the
mixture. The homogenizer helps to attain equal amount of fat.

Cooling and resting to blend flavors

The mixture is piped back to the pasteurizer where cold water flows on
one side of the plates as the mixture passes on the opposite side. In this
manner, the mixture is cooled. Then the mixture is pumped to tanks in
a room set at 36°F, where it sits for four to eight hours to allow the
ingredients to blend.
Flavoring the ice cream

The ice cream is pumped to stainless steel vats. Then the flavorings are
piped into the vats and blended thoroughly.

Freezing to soft-serve consistency

Now the mixture must be frozen. It is pumped into continuous

freezers. The temperature inside the freezers is kept at -30°C, using
liquid ammonia as a freezing agent. While the ice cream is in the
freezer, air is injected into it. When the mixture leaves the freezer, it
has the consistency of soft-serve ice cream.

Adding fruit and sweetened chunks

If chunks of food such as nuts or dry fruits or cookie pieces are to be

added to the ice cream, the frozen mixture is pumped to a fruit feeder.
As the mixture passes through the feeder, a star wheel pushes the food
chunks into the ice cream. The mixture then moves to a blender where
the chunks are evenly distributed.
Packaging

Automatic filling machines drop preprinted pint or cardboard cartons

into holders. The cartons are then filled with premeasured amounts of
ice cream. The machine then places a lid on each cartons and pushes it
onto a conveyer belt. The cartons move along the conveyer belt where
they pass under a ink jet that spray-paints an expiration date and
production code onto each carton.

Hardening

Before storage and shipping, the ice cream must be hardened to a

temperature of -18°C in cold rooms. The ice creams must be stored in
cold rooms for 16 hours before transporting them.

TRANSPORTATION AND DISTRIBUTION:

From cold storage, the ice cream is now ready to be shipped and
distributed in entire city. They are transported in a van which is
equipped with refrigerator.
 PRODUCT RANGE

Family pack: Available in 500ml pack and in all flavors like Butterscotch,
strawberry, vanilla, mango, raspberry etc.

Cup ice-cream and ball ice-cream: Available in 40ml and in 100ml and
in all flavors like vanilla, mango, butterscotch etc.
Cone ice cream: Available in 110ml, 50ml and in all flavors like vanilla,
butterscotch etc.

Candy bar: Available in choc-bar, mini choc-bar, raspberry, rose milk

bar flavors.
 MACHINERIES AND EQUIPMENTS
Jamaai ice cream factory uses many kinds of machinery and
equipments like condensed milk plant, pasteurization plant, mix storage
tank, mix ageing tank, continuous freezer tank, cold rooms, manual
candy and jumbo tank.
LABOURERS:
There are around 200 to 300 skilled, semi-skilled and non-skilled
employees in Jamaai ice cream factory.

PLANT LAYOUT AND MATERIAL HANDLING:

The men and machinery are arranged in available space in Jamaai ice
cream factory. This enables them to have a smooth flow of production.

Material handling in Jamaai ice cream factory is less. The main objective
of firm is to reduce time and cost which is possible due to less material
handling.

CONCLUSION

Jamaai ice cream factory is well organized and a well developed

company.

The industrial visit to the Jamaai ice cream factory was a wonderful
visit. Our visit to the manufacturing unit helps us to learn about how an
organization runs its production unit successfully.

The visit was highly educational and helped each one of us to get a
deep understanding of the marketing, production process, plant layout,
machinery and equipment and range of the product.

We came to know about the process used to manufacture ice cream.

Improvements are needed in certain areas of storage, packing and

hygiene of ice creams and different types of problems encountered in it
and how they overcome those problems.