unit-11 EN.pdf

UNIT UN IT 11

SOFTY SOFT Y AN AND D NOV NOVEL ELTI TIES ES – DEFINITION, COMPOSITION, LEGAL STANDARDS AND METHOD OF MANUFACTURE MANUFACTURE

Structure

11.0 Objectives 11. 1.1 1

Introduction

11. 1.2 2

Leg egal al Sta tan ndar ard ds

11. 1.3 3

Form Fo rmul ulat atio ion n of So Soft ft Ser Serve ve Ice Ice Cre Cream am

11.4

Composition

11. 1.5 5

Manu Ma nufa fact ctur urin ing g Pr Proc oced edu ure ress

11. 1.6 6

Icee Cre Ic Cream am Novel elti tiees •

Method of Manufacture

•

Chocolate Coatings

•

Ice Cream Cakes and Pies

•

Aufait Ice Cream

•

Other Novelties

•

Cassata Ice Cream

•

Chocolate Jam Sticks

•

Quiescently Frozen Stick Items

11.7

Indi In dige geno nous us Fr Froz ozen en Da Dair iry y Pro Produ duct ctss

11.8

Let Us Sum Up

11.9

Key Words

11.1 1.10 0 So Some me Us Usefu efull Boo Books ks 11.1 11 .11 1 Answer Answerss to Check Your Progr Progress ess

11.0

OBJECTIVES

After reading this unit we should be able to: •

•

state the meaning of softy and novelties  prepare recipes for these produ products cts

•

explain the method of manufacture of these products

•

give the legal requirements of these products

•

give the composition of these products

11. 1.1 1

INTRODUCTION

Softy or ‘scoop able ice cream’ was first firs t marketed in earnest in England in 1975. The aim was to produce a type of ice cream that was scoopable at -18 C and that had a good creamy consistency, slow meltdown properties and good storage stability sta bility..

59

Frozen Dairy Products

While hard ice cream has been the t he dominant frozen dessert produced world wide for many years, other frozen dessert products have their t heir niche, and in many countries are more popular than ice cream. The American market in recent years have seen se en the introduction of a number of other dairy and non dairy soft serve products, such as frozen yoghurt, sorbets and smoothies. As the name implies, soft serve products are not hardened, and its is their soft, creamy texture that the public finds so appealing. They are easy to consume, thus  providing instant gratification. They are especially easy to lick, a characteristic  partic  par ticula ularly rly enj enjoye oyed d by chi childr ldren, en, who mak makee up 50 per cen centt of the con consum sumer er bas basee for  soft serve products. Such products also lend themselves to decreased labour costs, as evidenced by the growing numbers of consumers willing to serve themselves from soft serve freezers in supermarkets and convenience stores and restaurants. Other than the investment in the equipment, handling soft serve products is a relatively low-cost operation. The equipment takes up little space and is easy to operate. The  products  prod ucts incre increase ase prof profit it marg margins ins and are self-p self-promo romoting ting when the machi machinery nery is in  publicc view  publi view.. Two major catego categories ries of soft serve produ products, cts, low fat and non fat soft ice cream and frozen yoghurt, attained atta ined amazing sales growth during the late 1980s  because  beca use of inte intense nse con consume sumerr inte interest rest in the diet and heal health. th.

11. 1.2 2

LEGAL STANDARDS

In India there are no separate legal standards for soft serve ice cream. crea m. The Prevention of Food Adulteration Act (1954) has specified speci fied the same standard s tandard for ‘Softy’ as that of ice cream.

11.3 FORM FORMUL ULA ATI TION ON OF SO SOFT FT SE SER RVE IC ICE E CREAM There are several ways of obtaining softness in ice cream, and sometimes these may  be com combin bined ed if req requir uired. ed. The fol follow lowing ing tech techniq niques ues are use used: d: •

Addition of an anti-frost preparation preparat ion of carbohydrate nature, including MSNF

•

Increase of the overrun

•

Selection of specific emulsifiers/ stabilizers.

The first is the most important point, and the effect of using freezing freez ing point depression factors is discussed below: i.

Lower the Fre Freeezing Po Point

In traditional ice cream cre am there are various ingredients, ingredient s, but not all of them have an influence on the freezing point of ice cream mix Degree of freezing point depression

60

Fat:

Of no importance

MSNF:

Limited importance (contains lactose and salts)

Sugars

Great importance (give the main effect)

Emulsifier/stabilizer

No imp impor orta tanc ncee

Overrun

Great importance

Consequently, the freezing point depression is sought from lactose and salts of MSNF Consequently, as well as the sugars. ii

Effec Ef fectt of of MSN MSNF F on on Free Freezi zing ng Po Poin intt Dep Depres ressi sion on

Softy and Naovelties – Definition, Composition, Legal Standards Standar ds and Method of Manufacture

It is known that MSNF consists of approximately approximate ly 8% minerals, 39% protein and 53% lactose. Lactose is a disaccharide that is in the dissolved state. It lowers the freezing point just like li ke ordinary sugar. The salt content will also have an influence on the freezing point and generally it may be assumed that the t he MSNF will depress the freezing point to the same extent as a 40-50 DE glucose syrup. Lactose, is an important part of MSNF, MSNF, but is only partially soluble. If the MSNF factor (i.e. parts of MSNF per 100 parts of water): i.e.

%MSNF ×100 % water  water 

is increased to more than 17, the result will be the risk of a sandy ice cream. By means of enzyme lactase, the lactose may be hydrolyzed into monosaccharides, glucose and galactose which are more soluble and these sugars will lower the freezing  point  poi nt more than the lacto lactose. se. However, MSNF has a limited effect on the freezing free zing point depression. The main effect is achieved by the sugars, which are present. iii. ii i. Eff Effect ect of Suga Sugars rs on Freez Freezing ing Poin Pointt Depress Depression ion

The freezing point of an ice cream mix is first of all dependent on the amount of  dissolved solids. The more are the solids dissolved (in the genuine solution), the lower the freezing point. The sugars produce a lowering loweri ng of the freezing point and it is its molar concentration that determines the freezing freezi ng point of the ice cream mix. In order to survey the effect of different products, it is necessary to introduce two factors that are related to lowering of the freezing point and the sweetening ability of  sugars. The factors are: Freezing point depression factor (FPDF) and Relative sweetness Table 11.1 : Freezing point depression and relative relativ e sweetness of some sweeteners Carbohydrate Sucrose Glucose syrup 42 DE High fructose corn syrup (42% fructose) Dextrose Fructose Invert sugar Lactose Galactose Sorbitol Glycerol Ethanol

Average molecular weight 342 445 190

FPDF Relative sweetness 1.0 1.0 0.8 0.3 1.8 1.0

180 180 180 342 180 182 92 46

1.9 1.9 1.9 1.0 1.9 1.0 3.7 7.4

0.8 1.7 1.3 0.2 0.3 0.5 0.8 -

In the above table, sucrose was chosen as the datum point and the FPDF and relative sweetness of each sweetener is compared with it.

61

Frozen Dairy Products

For example, the same amount of dextrose will lead to greater freezing point depression than sucrose due to the difference in molecular weights, and conversely glucose syrup will produce a less freezing point depression than sucrose. By combining different sweeteners, it is possible to produce desired softness and a nd relative sweetness. Experience has shown that ice cream with FPDF of about 15 will be relatively hard at -18 C and not scoopable, whereas scoopable ice ic e cream should have a FPDF of  around 20-25. A well known and easy way of obtaining scoopable ice cream is to add 2-3% glycerol. The following recipe shows the effect of keeping the total sweetness constant: Recipe: Fat

10.0%

M SN F

10.7%

Sucrose

11.0%

Glucose solids

3.0%

Glycerol

2.0%

Emulsifier/stabilizer

0.7%

Total solids

37.4%

Calculation of FPDF and Relative sweetness sweetness

FPDF

Relative

Sucrose, 11%

11 × 1 = 11

11 × 1 = 11

Glucose solids, 3%

3 × 0.8 = 2.4

3 × 0.3 = 0.9

Glycerol, 2%

2 × 3.7 = 7.4

2 × 0.8 = 1.6

20.8

13.5

The addition of 2% glycerol produces a FPDF of 20.8 which will be suffi cient to give the product scoopable properties. The effect of other combinations can be considered, considere d, especially if a combination of  saccharides can be used to produce acceptable softness and sweetness in the final  product. A recipe which can be considered without the use of glycerol is shown  belo  be low: w: Recipe:

62

Fat

10.0%

MSNF

10.6%

Sucrose

4.5%

High fructose corn solids

6.0%

Glucose solids

2.0%

Dextrose

4.5%

Emulsifier/stabilizer

0.7%

Total solids

37.3%

Calculation of FPDF and Relative sweetness FPDF

Relative sweetness

Sucrose, 4.5%

4.5 × 1 = 4.5

4.5 × 1 = 4.5

Glucose solids, 2%

2 × 0.8 = 1.6

2 × 0.3 = 0.6

High fructose corn solids, 5%

5 × 1. 1.8 = 9. 9.0

5 x 1 = 5.0

Dextrose, 4.5%

4.5 × 1.9 = 8.6

4.5 × 0.8 = 3.6

23.7

Softy and Naovelties – Definition, Composition, Legal Standards Standar ds and Method of Manufacture

13.7

The correct choice of saccharides can make it possible to produce a scoopable ice cream with the same solids and total sweetness as that of regular ice cream.

11. 1.4 4

COMPOSITION

The differences between soft serve and regular ice cream crea m include: •

Composition

•

Freezing procedures

•

Stability and whipping properties of the mix

•

Maintenance of dry, smooth, stiff characteristics of the product as drawn from the freezer.

i)

Fat: Soft serve ice cream has a lower butter fat than the hard product, but it is difficult for the consumer to tell because the soft state allows all ows full flavour. Soft Soft serve ice cream normally has a fat content between 6 to 10% range. If fat content is low, i.e. less than 4%, the product tends to become coarse, weak  and icy. icy. If the fat content is high hi gh (above 12%) freezing freezin g problem is encountered. encountere d. This involves possible fat separation, and also, the product becomes too rich and less palatable.

ii)

Milk So Milk Solid lids-N s-Not ot-F -Fat at (MS (MSNF NF): ): The MSNF content of soft frozen froze n products varies somewhat inversely with the fat content and can be as high as 13% for a low fat formula. MSNF serves for f or provide proper firmness of body. In products having a high MSNF content, the lactose may separate during duri ng freezing and cause a sandy defect. Normally soft serve products consists of 11-14% MSNF. MSNF.

Soft serve mixes should have a slightly lower MSNF than normal ice crea m, as a slightly lower MSNF (MSNF factor 16-16.5) contributes to a higher degree of fat destabilization, thus, ensuring better stand-up and slower meltdown (a MSNF factor of 17 is recommended for plain, hardened ice cream). Since the soft-serve mix is exposed to a mechanical mec hanical treatment for alonger period of  time in the freezer, this can cause excessive exces sive churning of fat, resulting in a greasy greas y texture. This can be avoided by incorporating whey proteins which impart greater  stability to fat emulsion, and consequently less fat destabilization and ‘churning out’ effect of the emulsifier. emulsifi er. Replacement of 10-15% MSNF with whey powder  adds to the freshness of soft-serve ice cream and a nd fat destabilization is also  broug  bro ught ht und under er con contro trol. l. iii) Sugar: The sugar content of soft serve products is 13-15%, which is slightly lower than for regular ice cream. The amount of corn sugar used to replace 63

Frozen Dairy Products

cane sugar is limited to about 25% in order to avoid too low a freezing point. However, corn syrup solids, instead of corn syrup, can be added as they provide firmness and also raise the freezing freezi ng point slightly (corn syrup solids depress the freezing point less than corn syrup and sucrose) thereby enabling the drawing of ice cream at almost the same temperature as normal ice cream. Stiffness and dryness of mix is extremely important for getting a smooth, creamy finished product from the soft serve freezer. Those Those characteristics are achieved  by two way ways: s: •

•

By reducing the sugar content of mix by 2-3% of that used for a hard ice cream product Drawing the product at lower temperature 21 to 22 F. This lower  temperature not only produces a stiffer product, but makes it immediately suitable for serving to public.

iv)) Emul iv Emulsi sifi fier erss and stabi stabili lizer zers: s: Higher amounts of emulsifiers and stabilizers are added to provided desirable whipping properties, smoothness, firmness and melting resistance.

Emulsifiers have several main effects in ice cream: •

•

•

To facilitate the dispersion dispersion of the fat in fine, uniform globules during whipping To promote and control destabilization destabilizat ion of the fat and to secure a good fat  protect  pro tecting ing mem membra brane ne aro around und the air cell cellss To aid aeration during freezing by permitting better air distribution with a smaller air cell size.

Thanks to these effects an ice cream with a creamy cre amy consistency, slow meltdown and improved storage stability can be produced. These are exactly e xactly the properties that are needed in scoopable ice cream. It is advantageous to increase the addition of emulsifier in scoopable ice cream, due to increased level of the liquid water phase at any given temperature. The main effect of stabilizers in ice cream systems is to bind water resulting in higher mix viscosity and superior body in the finished ice cream as well as controlling the mobility of the residual aqueous phase. As mentioned above, there is more liquid phase in scoopable ice cream, cre am, which means that more stabilizer is needed to bind the water present. A 5 to 10% increase in emulsifier/ stabilizer content is advisable. v)

Other add additives: Products like calcium sulphate can be used at the rate of  0.12% to produce dryness and stiffness in ice cream. crea m.

Check Your Your Progress Progre ss 1

1.

Listt the differ Lis different ent ways ways norm normall ally y used used for obta obtaini ining ng softn softness ess in ice ice cream. cream. ............................................ ..................... ............................................. ............................................ ............................................ ........................... ..... ............................................ ..................... ............................................. ............................................ ............................................ ........................... ..... ............................................ ..................... ............................................. ............................................ ............................................ ........................... .....

2. Give a recipe for soft serve ice cream. ............................................ ..................... ............................................. ............................................ ............................................ ........................... ..... 64

......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ 3.

How Ho w soft soft serv servee ice crea cream m diffe differs rs form form regu regular lar ice ice cream cream??

Softy and Naovelties – Definition, Composition, Legal Standards Standar ds and Method of Manufacture

......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ 4.

What has to to be don donee to get get the prop proper er stiffnes stiffnesss and dryn dryness ess in soft serve serve ice cream? ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........

11.5

MANU MA NUF FAC ACTU TURI RING NG PRO PROCE CEDU DURE RE

i)

Sel elec ecti tion on of in ingr gred edie ien nts: Fresh, sweet dairy products should be preferred for making soft serve mix in order to obtain a good quality product. Generally, cane sugar is used but a part of it is replaced with dextrose or corn syrup. The The selection of ingredients should be based on the composition given in section above.

ii)) ii

Mixin Mixi ng of ing ingrred edie ient nts: s: T  To o avoid difficulties in mixing, pre-calculated quantities of dry ingredients, i.e. milk mi lk power, sugar and stabilizer should be mixed mixe d in a lot. Similarly, the liquid ingredients, viz., milk and cream, etc. should be mixed separately in a container. The dry mixture shall be incorporated within the liquid ingredients mixture gradually with constant stirring and heating to the homogenization temperature of 65.5 C.

iii) Homo Homoge geni niza zati tion on: In order to avoid fat separation, clumping of fat and fat churning in soft ice cream, the mix should be homogenized in two stages. First at a pressure of 2500 psi. and then at a pressure 500 psi. iv)) Past iv Pasteu eurriz izat atio ion n: To To safeguard health heal th consumers by means of destroying des troying all the  patho  pa thogen genic ic and dis diseas easee pr prod oduci ucing ng org organi anisms sms pre presen sentt in th thee mix mix,, it mu must st alw always ays  be pasteurized. pasteurized. Pasteurization is normally done done at 80 C for 25 seconds by High Temperature Temperature Short Time (HTST) method or at 69 C for 30 min. by Batch method. v)

Ageing of mix: The mix is to be aged at temperatures 2-5 C for at least 4 to 6 hours before freezing.

vi) Freezing: A soft ice cream freezer, apart from freezing a portion of water of  ice cream mix, also incorporates incorporat es the air in the mix to obtain a swell in volume or  ‘overrun’. A soft ice cream freezer free zer is very similar to the batch freezer fre ezer of ice cream. It is usually a self contained machine in which the low pressure refrigeration refrigerat ion system is either directly attached, or is adjacent to the freezer.

The design of the dasher is such that it gives a good degree of aeration aera tion to the mix as it freezes and can operate for a long period of time without undue breaking down of  the ice cream mix. Excessive speed of the dasher causes too much air to be incorporate, and adversely affects the body of ice cream if the dasher ran for extended exte nded

65

Frozen Dairy Products

 periods of time. The refri  periods refrigerat geration ion syst system em is so desi designed gned that the freez freezer er cylin cylinder der is kept at the proper temperature for a soft serve ice cream for an indefinite period of  time. Most of these freezer use Freon as a refrigerant. In this case, they often use a thermo valve control rather than the flooded system. Care and maintenance of this type of freezer consists mainly of keeping the scraper blades properly sharpened, and ensuring that the refrigeration system is properly adjusted. The automatic cycling of ice cream can cause major problems including fat separation, occurrence of sandiness due to lactose crystallization and coarse texture. Soft server frozen products are usually drawn from the freezer at -6.5 to -7.5 C. The overrun of soft serve varies between 40-60% depending on the total solids content. It is possible to achieve high overrun and desired body and texture characteristics character istics on a product with a high solids content. Table 11.2: Overrun and serving temperatures for different types of ice cream Products Soft serve Sherbet Milk shake Hardened ice cream

Overrun, % 40-60 30-50 50-80 80-100

Serving temperature, C -5.5 to -6.6 -6.1 to -7.2 -2.2 to -3.3 -12.8 to -15.0

11.6 IC ICE E CR CREA EAM M NO NOVEL ELTI TIE ES The term ‘novelty’ means something unique. As it related to ice cream, crea m, we mean any single-serve portion-controlled porti on-controlled product. Worldwide, Worldwide, especially especial ly in Europe, ice cream novelties enjoy an even bigger market. Every shape size, and flavour are being offered : from ice cream and frozen yoghurt to sorbets and non fat products. Methods of Preparation

Ice cream novelties are prepared either on a brine system or through an extrusion system. Using the brine system, semi-frozen ice cream is poured into molds that are  placed inside a brine tank to freeze the product at -20 F. F. The extrusion method enables a manufacturer to produce unusual types of novelties that are impossible to  produce  produ ce on a brine system system.. Using the extrusion method, the ice cream must be frozen to certain stiffness so that it retains its form between the time it is extruded until it enters a hardening tunnel. The ice cream is drawn dr awn from the continuous freezer fre ezer at 20-22 F. The external contour  cont our  of the slice can be almost of any desired shape of the extrusion nozzle. Complex extrusions utilizing more than one flavour or colour can be produced from multiflavour extrusion nozzles supplied by more than one continuous freezer barrel. By  placing different extrusion devises inside each other other,, faces with eyes, noses and mouths can be formed, as well as other intricat intricatee designs. Semisolid ice cream crea m is drawn either vertically vertical ly or horizontally. As the stiff extruded ice cream flows through the extrusion nozzle, portions of appropriate size are cut off   by an ele electr ctrica ically lly hea heated ted wir wire. e. In ver vertic tical al ext extrus rusion ion,, the fla flatt po porti rtion on of ice cre cream am fal falls ls  precisely onto a continu continuous ous row of stainless steel supporti supporting ng plates fastened to a conveyor chain which carries the portions into the hardening tunnel for rapid freezing. The temperature tempera ture in the hardening harde ning tunnel is usually usual ly in the range -45 F to -50 F. A 10% ice cream butter fat fa t mix with 85-100% overrun is most commonly used. 66

i.

Chocolate Coatings

More than 1/3rd of all ice cream cr eam novelties produced have some kind of exterior  chocolate coating. Chocolate bars consist of vanilla ice cream stick sti ck which has been dipped in chocolate coating. The composition of chocolate coating can be the following (on weight basis):

Softy and Naovelties – Definition, Composition, Legal Standards Standar ds and Method of Manufacture

Chocolate mass : 65-70 parts Coconut oil : 27-32 parts Cocoa butter: 1-1.5 parts Dextrose : 1-1.5 parts Lecithin : 0.3 – 0.4 parts Refined deodorized coconut oil is added as a thinner, to increase the coating ability. The quantity of coconut oil will vary with the amount of chocolate mass. Higher  amount of chocolate mass will require more quantity of coconut oil to avoid the excessive viscosity viscosit y. Coconut oil is preferred since other oils oil s have melting points which are too low for satisfactory use in coatings ii.

Icee Cre Ic Cream am Ca Cake kess and and Pie iess

These products can be made with freezer attachments atta chments designed for filling the cake or the pie plate. The cake plate is usually inse rted into a cardboard package the support the form of cake during handling and delivery deli very.. Ice cream pies can be modified by using fruit flavoured gelatin, instead of the filling of preserved fruit or fruit ice cream which is ordinarily used. The pie crusts are about ½ inch thick and can be made by hardening vanilla ice cream between two plates. Closed or open pies can be made by this procedure. The pies and cakes can be decorated with whipped cream. iii. Auf ufai aitt Ice Ice Cr Crea eam m

Aufait ice cream usually consists of a layer of fruit between two layers of ice cream. iv.

Oth ther er No Nove velt ltie iess

Variegated or rainbow ice cream is made by mixing several different colours as the  produ  pro duct ct is pac packag kaged. ed. Th Thee var varieg iegate ated d ice cre cream am sun sundae dae,, and oth other er col colour ourful ful pro produ ducts cts are packaged in transparent plastic container to have a good consumer appeal. v.

Cassata Ic Ice Cr Cream

This is essentially ice cream on a sponge cake. Hemispherical moulds of aluminum are used in making this ice cream. The outer layer is usually usua lly made of chocolate ice cream. Different varieties of ice cream constitute the middle and inner layer layer.. The ice cream which constitutes the outer layer is first firs t filled in the mould (outer mould) from the freezer. Another mould which is smaller in size, is inserted into the first mould and  pressed  press ed so that the ice cream occu occupies pies the annu annular lar space betw between een the two mou moulds. lds. This ice cream is hardened and the smaller smalle r mould is taken out. Ice cream is now filled again into the mould and another smaller mould of a different size is inserted and pressed lightly. lightly. This ice cream layer now forms the middle layer. layer. The ice cream is hardened and the smaller small er mould taken out. Now a third variety of  ice cream is filled into the outer mould and this ice cream constitutes the innermost layer. The mould is hardened and ice cream is taken ta ken out by dipping the mould in

67

Frozen Dairy Products

slightly warm water. Now the three layer ice cream is inverted on the sponge cake to which thin coating of whipped cream has been applied. The whipped cream serves the purpose of an adhesive between betwee n the cake and ice cream. This cassata cassa ta ice cream is transferred to the cold store or hardening tunnel so that it becomes sufficiently hard for slicing into small pieces. vi.. Ch vi Choc ocol olat atee Jam Jam Sti Stick ckss

These are made by coating vanilla sticks with white chocolate and injecting the vanilla portion with a flavoured syrup of jam base which constitutes the innermost core. A white chocolate coating is made by adding a thinner thinner,, cocoa butter and an emulsifier. Usually coconut oil is added as a thinner and lecithin is added as an emulsifier emulsifier.. An appropriate amount of colour (oil soluble) is added to the coating so that it is characteristic of the flavour added to the syrup or jam base. The The total solids content of the syrup or jam base is so adjusted that its freezing freez ing point is much lower than the vanilla portion. But the syrup should have a sufficiently high viscosity so that it does not drip while eating. A syrup or jam base consists consist s of sucrose, glucose syrup, syr up, citric acid, stabilizer, water, fruit pulp or concentrate and flavour fla vour.. vii.. Quies vii Quiescentl cently y Froze Frozen n Stick Stick Items

These items include water ice frozen without overrun in a stick and cream on a stick  which has ice cream centre with quiescently frozen outer section. Water ice: The following formula is suggested suggeste d for an ice base (on weight basis) basi s) Water : 85-95 parts Cane sugar : 20-23 parts Glucose syrup : 5-7 parts Stabilizer : 0.25-0.35 parts Citric acid : 0.35-0.50 parts Brix : 22-24 1.

Weigh the stabil stabilizer izer carefu carefully lly and and mix it it with cane suga sugarr in the the ratio 1:3 parts parts by by weight and add the required amount a mount of water. Then Then agitate until it is fully suspended. It is necessary to maintain the temperature t emperature of the mixture between 60-70 C to fully dissolve the stabilizer. st abilizer.

2.

Add the remain remaining ing amou amount nt of of cane suga sugarr and the requi required red amou amount nt of gluc glucose ose syrup, and agitate until it is fully dissolved. If necessary, neces sary, homogenize homogenize at 100  bars to obt obtain ain hom homoge ogenou nouss mix mix..

3.

Pasteurize Pasteur ize at 80-8 80-85 5 C for 20-4 20-40 0 sec and and cool cool the mixt mixture; ure; add add citric citric acid acid,, desired colour and flavour. fla vour.

4.

Ageing for Ageing for 4 hours hours to impa impart rt a smooth smooth body body when gelat gelatin in or agar agar agar is is used as a stabilizer. stabilize r.

Pour the mix into the mould and allow sufficient sufficie nt space in the pocket for expansion expansi on during freezing. Place the moulds in the brine tank at -25 to -30 C. On partial freezing, insert the sticks into the mould pockets (the water ice should be  justt suf  jus suffic ficien iently tly firm and har hard d to ho hold ld the stic sticks) ks).. 68

Freezing us usually accomplished in 15-20 min. The frozen sticks are then taken out  by imm immersin ersing g the mou mould ld in hot wate waterr for a few seco seconds. nds. For a cream-on-a-stick item, a special filler fil ler attachment can be used so that in one operation, a freezer can be used to freeze the ice cream to 100% overrun for the centre, and a second freezer to freeze the ice or sherbet sher bet shell to 10-15% overrun for  the shell.

11.7 i.

Softy and Naovelties – Definition, Composition, Legal Standards Standar ds and Method of Manufacture

INDI IN DIGE GENO NOUS US FR FROZ OZEN EN DA DAIR IRY Y PR PROD ODUC UCTS TS

Kulfi

It is a frozen dessert characterized c haracterized by slight whitish to brownish appearance, compact  body  bo dy,, icy tex textu ture re an and d nu nutty tty,, co cook oked, ed, car carame ameliz lized ed fla flavo vour ur.. It is po popu pular lar in the no north rthern ern and western parts of India. In the traditional process, milk is thickened in a shallow  pan with cons constant tant agita agitation tion.. Sug Sugar ar,, nuts nuts,, essen essence ce and colo colour ur are adde added d towa towards rds the finishing stages. Concentrated mass is poured into metallic moulds and frozen in a mixture of ice and salt. In the industrial process, the ingredients used are the same as for ice cream – milk, cream, skim milk powder, sugar and stabilizer. Water Water is added to dilute the mixture mi xture (not having stabilizer and a small amount of sugar), and the fat: MSNF ratio is maintained at 1.4:1. usually, the fat in the finished product is about 16%. The required quantity of ingredients are taken take n in an open steam kettle and the contents heated with vigorous agitation. When the mixture has been concentrated c oncentrated approximately two times, the stabilizer blended with little sugar (1:3 parts by weight) is added to the concentrated mix, and the heating and agitation is continued till the mixture has  been  bee n con concent centrate rated d thre threee time times. s. The con concen centrat trated ed mass is the then n coo cooled led pro prompt mptly ly and frozen in a batch freezer free zer to an overrun of 20-30%. Chopped nuts, almonds, pistachio, pistac hio, flavour and colour are added in the freezer. freeze r. The frozen mix is transferred immediately into the moulds having freezing pockets. Wooden Wooden sticks are inserted and the mix mi x hardened in a brine tank maintained at -23 to -30 C. The mould is then transferred into a tank having lukewarm water to defrost the bars so that they can be easily lifted from the freezing pockets. The bars are ar e wrapped in papers, put in corrugated boxes and placed in cold store until further distribution. ii.

Malai ka ka ba baraf:

It is popular in northern and western parts of India. It is similar to kulfi and prepared  by fr freez eezin ing g a mi mixt xtur uree of ma malai lai (h (heat eat de desic sicca cated ted/c /clo lotte tted d mi milk lk), ), su suga garr, nu nuts ts an and d ess essen ence. ce. This product has a plastic plast ic body, crunchy, icy texture , and delicate, nutty and caramel ca ramel flavour. Check Your Your Progress Prog ress 2

1.

Describ Des cribee how how mix mix is pre prepar pared ed for for soft soft serv servee ice ice cream. cream. ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........

2.

Givee the com Giv composi position tion of chocol chocolate ate coatin coating g used used in cho chocola colate te bars. bars. ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........ ......................................... ................... ............................................ ............................................ ............................................ .............................. ........

69

Frozen Dairy Products

3.

Give the drawi Give drawing ng tempe temperatu rature re and ove overrun rrun of soft soft serve serve ice ice cream cream and regu regular  lar  hardened ice cream? ............................................ ..................... ............................................. ............................................ ............................................ ........................... ..... ............................................ ..................... ............................................. ............................................ ............................................ ........................... ..... ............................................ ..................... ............................................. ............................................ ............................................ ........................... .....

4.

Describ Des cribee the the indus industria triall metho method d of pre prepar paratio ation n of kul kulfi? fi? ............................................ ..................... ............................................. ............................................ ............................................ ........................... ..... ............................................ ..................... ............................................. ............................................ ............................................ ........................... ..... ............................................ ..................... ............................................. ............................................ ............................................ ........................... .....

11.8

LET US SUM UP

There is a significant demand for ‘soft ice cream’. The term soft ice cream applies to those products which are marketed in the t he soft form, and are consumed immediately after they are drawn from the freezer freezer.. The differences between soft serve ice cream and regular ice cream include : composition, freezing procedures, stability and whipping properties of the mix, and the maintenance of dry, smooth, stiff characteristics of the product as drawn from the freezer. The term ‘novelty’ means something unique. As it related to ice cream, crea m, we mean any single-serve portion-controlled product. Today, Today, machinery can c an produce protioncontrol portions of nearly every shape and size such as coated and uncoated bars, cups, fancy funny face and character bar and ice cream sandwiches. But the human element is still critical in the production of ice cream novelties. Indigenous frozen desserts include Kulfi, which is a frozen dessert characterized by slight whitish whitis h to brownish appearance, compact compac t body, body, icy texture and nutty, cooked, caramelized flavour. flavour. It is popular in the northern and western parts of India. In the traditional process, proce ss, milk is thickened in a shallow pan with constant agitation. Sugar, nuts, essence and colour are added towards the finishing stages. Concentrated mass is poured into metallic moulds and frozen in a mixture of ice and salt and Malai-ka baraf, which is similar to kulfi and prepared by freezing a mixture of malai (heat desiccated/clotted milk), sugar, nuts and essence. This product has a plastic body body,, crunchy,, icy texture, and delicate, nutty and caramel flavour crunchy flavour..

11.9

70

KEY WORDS

Cassata

: This refers to ice cream on a sponge cake.

Clumping of fat

: Aggregates of fat, which form at elevated temperatures under certain conditions of  homogenization homogenizati on of milk, cream, or ice cream mix. A second homogenization at lower   pressures (500 (500 psi.) aids in breaking up fat clumps that may have formed during the first stage of homogenization.

Coarse or icy texture

: This is the most common texture defect in ice cream. It indicates that the ice crystals are

large or not uniform in size, or that the air cells are too large. Cooked flavour

: A cooked flavour is due to chemical changes. Milk and milk products, when subjected subjecte d to high temperatures develop this flavour. f lavour. This flavour arises from the sulphydryl s ulphydryl groups activated by heat denaturation of whey  proteins and the proteins of fat globule membrane.

Freezing point of mix

: The temperature at which ice cream mix will freeze, approximately 27 to 28 F depending on the sugar content of the mix. Mix with lower sugar content will freeze at a slightly higher temperature.

Hardening of ice cream

: It refers to the second phase of freezing where freezing in cups/packages is accomplished without agitation. The time required for  hardening is the time necessary for the temperature of the center of the package to reach to –18 C.

Heat shock resistance

: Ability of ice cream to maintain its structure when it is subjected to extreme fluctuations in temperature.

Homogenization

: to bring about homogeneity; it refers to  break  br eakin ing g of fat gl glob obul ules es to les lesss th than an 2 mi micro crons ns so that a permanent and uniform suspension of the fat is obtained.

MSNF factor

: It is defined as the ratio of per cent MSNF to  per cent water present in the ice cream mix, multiplied by 100.

Overrun

: It is the increase in volume of ice cream over  the volume of mix, expressed as percent of  the volume of mix.

Sandy texture

: This is related to the presence of large lactose crystals in ice cream. Fairly large lactose crystals are hard to dissolve in the mouth and they cause a gritty sensation as though the ice cream contained sand.

Soggy body

: Ice cream which is heavy and somewhat wet in appearance.

Texture

: Texture is the attribute of a substance related rela ted to its finer structure- the size, shape and arrangement of the small particles. The texture of ice cream is i s dependent on the number, size, shape and arrangement of the ice crystals and other particles.

Weak body

: Ice cream is said sa id to have a weak body when it melts down to a liquid of low consistency. c onsistency.

Softy and Naovelties – Definition, Composition, Legal Standards Standar ds and Method of Manufacture

71

Frozen Dairy Products

Whipped cream

: Cream that contains enough butter fat to allow incorporation of air. The whipped cream owes its stability to the “islands of fat” that result from partial churning.

Whipping ability

: It refers to those properties of a mix which determine the rate at which air can be incorporated and the maximum overrun that can be obtained.

11.10

SOME USEF EFUL UL BO BOO OKS

Arbuckle , W.S.1986, Arbuckle, W.S.1986, Ice Cream, Crea m, 4th edition. Van Van Nostrand Nostra nd Reinhold Reinhol d Company,  New York. Bhandari, Vivek, 2001. Ice cream : Manufacture Manu facture and a nd Technology, Technology, 1st editio  edition, n, Tata Tata McGraw-Hill Publishing Co. Ltd., New Delhi. Hyde, K.A. and Rothwell, J., 1973, Ice Cream, Churchill Livingstone, Edinburgh. Sommer, H.H., 1951. 1951. The theory and practice of ice cream making, 6th edition. Olsen Publ. Co., Milwaukee, WI. Stogo, M., 1998. Ice cream and Frozen Desserts. A commercial guide to production and marketing, market ing, John Wiley and Sons, Sons , Inc., New York. York.

11. 1.1 11

ANSW AN SWER ERS S TO TO CHEC CHECK K YOU YOUR R PROG PROGRE RESS SS

Your answer should include i nclude the following followi ng points: Check your progress 1

1.

2.

i.

Additio Addi tion n of an an anti ti-f -fro rost st pr prep epar arat atio ion n of ca carb rboh ohyd ydra rate te na natu ture, re, in incl clud udin ing g MSNF

ii.

Incr In crea ease se of th thee ov over erru run n

iii.

Selectio Sele ction n of of specif specific ic emul emulsifi sifiers/ ers/ stab stabiliz ilizers. ers.

Recipe:

Fat

10.0%

M SN F

10.6%

Sucrose

4.5%

High fructose corn solids

6.0%

Glucose solids

2.0%

Dextrose

4.5%

Emulsifier/stabilizer

0.7%

Total solids 3.

72

37.3%

i.

Composition

ii.

Free Fr eezi zin ng pro roce cedu dure ress

iii.

Stabil Sta bility ity and and whip whippin ping g proper propertie tiess of the the mix

4.

i.

Reduci Redu cing ng th thee sug sugar ar co cont nten entt of of mix mix by 22-3% 3% of th that at use used d for for a har hard d ice ice cream product

ii.

Drawing Draw ing the prod product uct at lower lower temp temperat erature ure 21 to to 22 F.

iii.

Use of of calciu calcium m sulph sulphate ate at at the rat ratee of 0.12 0.12%. %.

Softy and Naovelties – Definition, Composition, Legal Standards Standar ds and Method of Manufacture

Check your progress 2

1.

2.

i.

Select Sele ctio ion n of of ingr ingred edie ient nts: s: Fre Fresh sh,, swee sweett dair dairy y pro produ duct ctss – par partt of can canee suga sugar  r  replaced with dextrose or corn syrup

ii.

Mixing of ingr Mixing ingredien edients: ts: mixing mixing of dry dry ingred ingredients ients with liqui liquid d ingredie ingredients nts heating to 65.5 C.

iii.

Homogenization Homogenizatio n at a pressure pressure of of 2500 psi. and and then at a pressure pressure 500 500  psi.  ps i.

iv.

Pasteuriza Paste urization tion at 80 C for for 25 secon seconds ds or or at 69 69 C for for 30 min.

v.

Ageing Age ing of mix: mix: at 2-5 2-5 C for for at least least 4 to 6 hour hourss before before free freezin zing. g.

Chocolate Chocol ate mass mass : 65-70 65-70 parts; parts; Coco Coconut nut oil oil : 27-32 27-32 parts; parts; Coco Cocoaa butter: butter: 1-1.5 1-1.5  parts; Dextrose : 1-1.5 parts;Lecith parts;Lecithin in : 0.3 – 0.4 parts

3. Overrun Soft serve Hardened ice cream

4.

40-60 80-100

Drawing temperatures -5.5 to -6.6 -12.8 to -15.0

Milk, cream, skim milk powd powder er,, sugar sugar and stabil stabilizer izer - requi required red quant quantity ity of  of  ingredients are taken in an open steam kettle and the contents heated with vigorous agitation - concentrate approximately two times – blend in stabilizer  st abilizer  with little sugar- heating till mixture is concentrated concentra ted three times - cooled - frozen to overrun of 20-30% - transfer into the t he moulds having freezing pockets –  insert wooden sticks - hardened at -23 to -30 C

73