Task+6

Fresh milk sourced from dairy farmers in Yorkshire, chosen for high standards of milk quality and animal welfare. We get the milk which is semi-skimmed and pasteurized, because if we get raw milk, we will have to set up facilities for these processes and this will make the company invest more money, whereas it will also need energy sources like electricity, water, etc that will also increase the expense. Another reason is that there are a lot of dairy industries providing such milk products, we can get semi-skimmed & pasteurized milk in huge quantity and as we are buying in bulk, it won’t cost more than that required to produce in plant or it might cost slightly more.
 * __Product formulation specifications:__**
 * Milk (44%):**

Nutritional content ||||  Typical value per 100ml
 * GDA% values per 250ml  ||
 * Energy  ||   206KJ/49Kcal   ||   6.10%   ||
 * Protein  ||   3.4g   || ||
 * Carbohydrates  ||   5g   || ||
 * of which sugars  ||   5g   ||   14%   ||
 * Fat  ||   1.7g   ||   6.10%   ||
 * of which saturate  ||   1g   ||   13%   ||
 * Sodium  ||   0.1g   || ||
 * Salt equivalent  ||   0.1g   ||   5%   ||
 * Calcium  ||   122mg(15% RDA)   ||   38%   ||
 * Vitamin B12  ||   0.4��g(40% RDA)   ||   100%   ||
 * Cream (13.6%):**

The cream used is extra thick double fresh cream which is reduced fat and pasteurized.

Nutritional content:
 * Typical value per 30ml ||  GDA  ||  your GDA  ||
 * Energy ||  576KJ/140Kcal  ||  7%  ||  2000Kcal  ||
 * Protein ||  0.5g  ||   ||   ||
 * Carbohydrates ||  0.5g  ||   ||   ||
 * of which sugars ||  0.5g  ||  0.60%  ||  90g  ||
 * Fat ||  15.2g  ||  22%  ||  70g  ||
 * of which saturate ||  9.4g  ||  47%  ||  20g  ||
 * Salt equivalent ||  trace  ||  trace  ||  6g  ||


 * Semi-skimmed milk powder (9.8%):**

Milk powders contain all twenty-one standard amino acids, the building blocks of proteins, and are high in soluble vitamins and minerals. They are for sauces, custards and all culinary uses, excellent for beverages. The milk powders contain skimmed milk solids(24%), lactose, whey powder, vegetable oil, dried glucose syrup, sodium caseinate, acidity regulator E340(b), emulsifier E471, vitamins C, A & D.

Nutritional content:
 * || per 100g powder  ||  per 100ml reconstituted  ||
 * Energy ||  2008KJ  ||  221KJ  ||
 * Protein ||  12.2g  ||  1.3g  ||
 * Carbohydrates ||  61.9g  ||  6.8g  ||
 * of which sugars ||  61.9g  ||  6.8g  ||
 * Fat ||  20.4g  ||  2.2g  ||
 * of which saturate ||  13.8g  ||  1.5g  ||
 * Sodium ||  0.4g  ||  0.04g  ||
 * Vitamin A ||  231g 29% RDA  ||  25.4g 3% RDA  ||
 * Vitamin C ||  8.4mg 14% RDA  ||  0.92mg 2% RDA  ||
 * Vitamin D ||  4.9g 98% RDA  ||  0.54g 11% RDA  ||
 * Calcium ||  451mg 56% RDA  ||  50mg 6% RDA  ||


 * Emulsifier (Panodan) (0.1%):**

It can improve texture, air incorporation, melting resistance, taste in low sugar ice, immune health and digestive health. Panodan can also extend the product shelf life, reduce the cost, fat, sugar and calorie[1].

1. Carrageenan (0.02%)
 * Stabilizer:**

Carrageenans are used to add texture and stability to a broad range of products including dairy desserts, processed cheese, chocolate milk and fruity jellies. Carrageenans are also used in a variety of meat based products providing firmness and texture to sausages and sliceability and juiciness to cooked ham. 2. Guar gum (0.1%)

Guar gum is a powerful thickener that enhances the texture and consistency of a wide range of foods. As a thickener, guar gum is eight times more powerful than cornstarch, so only very small amounts are needed to thicken your food. It gives dairy the desired creaminess and homogeneity.


 * Saffron (0.09%):**

Saffron is the dried red stigmas of the flower Crocus Sativus Linnaeus. It is a natural way of adding colour to cooking and need to be used sparingly.

Nutritional Information (values per 100g)

Energy: 310 Kcal

Protein: 11.4g

Carbohydrates: 61.5g

Fat: 5.9g


 * Rose water (0.48%):**

It mostly contain [|citronellol], [|nonadecane] , [|geraniol] and [|phenyl ethyl alcohol] , and also [|henicosane] , 9-nonadecen, [|eicosane] , [|linalool] , citronellyl acetate, [|methyleugenol] , [|heptadecane] , [|pentadecane] , [|docosane] , [|nerol] , [|disiloxane] , [|octadecane] , and [|pentacosane]. Usually, [|phenylethyl alcohol] is responsible for the typical odour of rose water but not always present in rosewater products[2].


 * Sugar (14%):**

Granulated sugar is a term for a class of edible [|crystalline] [|carbohydrates], mainly [|sucrose] , [|lactose] , and [|fructose] , [|[3]] characterized by a [|sweet] [|flavor].

Nutritional value per 100g:

Energy: 1619 KJ (387Kcal)

Carbohydrates: 99.98g

Water: 0.03g

Riboflavin (Vitamin B2): 0.019 mg (1%)

Calcium: 1mg 0%)

Iron: 0.01mg (0%)

Potassium: 2mg (0%)

Use the drinking water which is filtered.
 * Water (18%):**


 * __Final product specifications:__**


 * Product name:** Low-fat Saffron Ice Cream with Rose Water


 * Size and packaging:** 1 litre plastic (Tub) container


 * Allergen declaration:** Contains: milk, carrageenan, guar gum, panodan and saffron


 * Shelf life and storage:**

Product needs to be kept at or below - 18ºC when stored. Shelf life under these conditions is 24 months from date of manufacture as indicated by the best before date. Once opened, consume within 3 days.


 * ** Nutrition Information ** ||
 * || ** Per 100g **  ||  ** Per 2 scoops(100ml) **  ||
 * Energy ||  793KJ  ||  336.8KJ  ||
 * Protein ||  2.99g  ||  1.27g  ||
 * Carbohydrates ||  23.02g  ||  9.78g  ||
 * of which sugars ||  23.02g  ||  9.78g  ||
 * Fat ||  9.84g  ||  4.18g  ||
 * of which saturate ||  6.2g  ||  2.63g  ||
 * Fat(%) ||||  4.2% (<5%)  ||
 * Overrun ||||  155.56%  ||


 * __Process specifications:__**

The processing factors that most affect quality in the ice cream industry are :


 * Time
 * temperature
 * contamination
 * hygiene and sanitation
 * equipment and methods
 * packing for product appeal
 * correctness of fill

Time

Aging time is one of the most important factors in manufacturing ice cream. The mix is then aged for at least four hours and usually overnight. This allows time for the fat to cool down and crystallize, and for the proteins and polysaccharides to fully hydrate. Aging provides the following functions: Improves whipping qualities of mix and body and texture of ice cream by providing time for fat crystallization, so the fat can partially coalesce; allowing time for full protein and stabilizer hydration and a resulting slight viscosity increase; allowing time for membrane rearrangement and protein/emulsifier interaction, as emulsifiers displace proteins from the fat globule surface, which allows for a reduction in stabilization of the fat globules and enhanced partial coalescence.

Another important factor is the time of freezing and mixing. It is a necessary process to make the mix incorporate with air.. This gives the product its characteristic lightness. Without air, ice cream would be similar to a frozen ice cube. 150kg/h continuous freezer is used, 0oC for 30sec in continuous freezer or 15min in batch freezer.

Temperature The temperature of aging, mixing&freezing and storage should be 0oC~4oC, 0oC and -13oC, respectively.

Contamination

The product can be contaminated in a number of ways during processing, for example by dirt, water, lubricating oil, unpleasant odours and flavours, and hair. In order to avoid such contaminations, some necessary measures should be taken. For example, keep the equipment clean before contacting with food stuffs, the operators should wash their hands before working, and wear protective clothing

Hygiene and sanitation

Ice cream is a food, and must be handled hygienically. The containers and those will contact with ingredients should be sterilized to make sure they are hygienic. For example, every time before we use homogenizer, it should be cleaned properly..

Equipment and methods Stainless steel tanks that receive milk from tanker trucks or drums, with or without the measurement and testing of the milk received. Rapid blenders without heating or pump-type mixers (triblenders) with funnels for the addition of powders and ice-cream mixture circulation systems. The equipment combines homogenizing, sterilizing and CIP as a continuous working unit special for ice cream processing functions. Continuous ice-cream freezers that can be equipped with double pumps for ice-cream mixture and air injection.

Packing for product appeal The eye appeal and finish of the product is important. The packaging should include the following requirements:

The product packaging label should give a picture of the product inside, by adding a photo of the product on the package. The colour of the package and label should be tempting, the font used to describe the product on the label must be attractive. Made of strong and unbreakable plactic. It should have the capacity to hold 1 litre of ice cream. The packaging material should be nonreactive to ice cream and recyclable, e.g. PET. The appearance of the packaging should be oval shaped. The box should be sealed automatically by the equipment and easy to be open. The label should have the information including product name (highlighted), company name, ingredients, allergens, nutritional composition, shelf life, net weight or volume, vegetarian sign and storage information.

Yield and efficiency The efficiency of the process is important factor affecting profitability, and responsibility for these in the larger firms usually falls on production and method study staff, but in small firms the job may conveniently be combined with QC. Maximum yield and high efficiency depend on close supervision of such things as machine settings such as the speed of homogenizer.


 * Reference:**

[1] http://www.danisco.com/products/food_beverages/solution_finder/frozen_desserts/ice_cream

[2] Loghmani-Khouzani H, Fini Sabzi O, Safari J H (2007). “Essential Oil Composition of Rosa damascena��? Scientia Iranica 14 (4), pp 316-319. [|Sharif University of Technology, Research Note]

[3] [|"IUPAC Gold Book - sugars"]. Goldbook.iupac.org. 2009-09-07. [|http://goldbook.iupac.org/S06088.html. Retrieved 2009-12-20].