Detailed Project Report on ice cream stabilizer

ICE CREAM STABILIZER
[CODE NO.3746]


Ice cream is a complex food colloid that consists of air bubbles, fat globules, ice crystals and an unfrozen serum phase. Ice crystals and air bubbles are generally in the range of 20–50 μm. The air bubbles are usually to some extent coated with fat globules and the fat globules are coated with a protein/emulsifier layer. The serum phase consists of the sugars and high molecular weight polysaccharides in a freeze-concentrated solution. Various steps in the manufacturing process, including pasteurization, homogenization, ageing, freezing, and hardening, contribute to the development of this structure. Proteins and emulsifiers compete for inter facial space during the homogenization of the fat and the creation of the mix emulsion. Following homogenization, the emulsion is further affected by changes occurring during the ageing step, viz.,crystallization of the fat and rearrangement of the fat globule membrane to the lowest free energy state. This emulsion then undergoes both whipping and ice crystal formation during the dynamic freezing process, which contributes to the development of the four main structural components of the frozen product: discontinuous foam, a network of partially coalesced fat surrounding the air bubbles, ice crystals, and a continuous, freeze-concentrated, unfrozen aqueous solution

Stabilizers and emulsifiers have been conventionally used in ice cream as additives. Recently, there has been a tendency towards ‘all natural’ or ‘natural’ products which have given rise to the so called premium ice cream which is supposed to contain no additives. Yet because of the quality enhancing ability of stabilizers and emulsifiers, they remain as important ingredients for most ice creams and frozen desserts.

Stabilizers are substances which make it possible to maintain the physico-chemical state of a foodstuff; stabilizers include substances which enable the maintenance of a homogenous dispersion of two or more immiscible substances in a foodstuff and include also substances which stabilize, retain or intensify an existing colour of a foodstuff. Emulsifiers are surface active agents which improve the sensory quality of ice cream by aiding the whipping process, improve air cell distribution and enhance the products heat shock resistance. Despite their name, emulsifiers are actually used in ice cream to de-emulsify some of the fat.

Ice cream stabilizer is one of the important chemical or combination of chemicals formed by microbial origin, animal origin or vegetable origin. In case of vegetable origin the gum like arabic, acacia, guar gum, agar, carragheen etc. plays very important role. The gum is used as stabilizer the product for body and increases melting point, gelling property, texture, mouthfeel etc.

Over the years, the term gums was used to denote a wide range of compounds including polysaccharides, terpenes, proteins and synthetic polymers. Today, the term more specifically denotes a group of industrially useful polysaccharides or their derivatives that hydrate in hot or cold water to form viscous solutions or dispersions.

Gums are classified as natural and modified gums. Natural gums include seaweed extracts, plant exudates, gums from seed or root and gum obtained by microbial fermentation. Modified (semisynthetic) gums include cellulose and starch derivatives and certain synthetic gums such as low-methoxyl pectin, propylene glycol alginate, triethanolamine alginate, carboxymethyl locust bean gum and carboxymethyl guar gum.

The  polysaccharides  are  classified on the  basis  of  the dominant  sugar constituent or constituents or the presence of  a particular type of functional group, eg., sulfate ester.

Gums are used in industry because their aqueous solutions or dispersions posses suspending and stabilizing properties. In addition, gums may produce gels, act as emulsifiers, adhesives, flocculants, binders, film formers, lubricants or friction reducers, depending on the shape and chemical nature of the particular gum.


COST ESTIMATION


Plant Capacity            500 Kg/Day       
Land & Building (500 sq.mt.)      Rs. 68 Lac         
Plant & Machinery                      Rs. 16 Lac     
Working Capital for 1 Months     Rs. 68 Lac
Total Capital Investment              Rs. 1.58 Cr
Rate of Return            29%                   
Break Even Point             58%                


INTRODUCTION    
PROPERTIES OF ICE-CREAM STABILIZER    
DIFFERENT FOOD ADDITIVE STABILIZER AND THEIR PROPERTIES    
CLASSIFICATION OF STABILIZERS    
FORMULATION OF ICE CREAM STABILIZER    
MANUFACTURING PROCESS OF ICE CREAM STABILIZER    
PROCESS FLOW DIAGRAM    
OTHER FORMULATION OF ICE CREAM STABILIZER    
STABILIZER IN ICE CREAM    
STABILIZER AND ITS ROLE IN ICE CREAM    
ROLE OF STABILIZERS IN ICE CREAM    
PROPERTIES OF STABILIZER INGREDIENTS    
A) SODIUM ALGINATE    
B) CARRAGEENAN    
C) LOCUST BEAN GUM    
D) GUAR GUM    
E) PECTIN    
F) XANTHAN GUM    
G) SODIUM CARBOXYMETHYL CELLULOSE    
H) GELATIN    
I) OTHER HYDROCOLLOIDS    
MILK PROTEINS    
BENEFITS OF STABILIZER USED IN ICE CREAM    
INCREASE MIX VISCOSITY    
TO PRODUCE SMOOTH AND CREAMY TEXTURE    
TO PROVIDE RESISTANCE TO MELTING    
RETARD OR REDUCE ICE AND LACTOSE CRYSTAL GROWTH DURING STORAGE    
WHICH STABILIZERS ARE USED TO REDUCE ICE CRYSTAL GROWTH AND RECRYSTALLISATION?    
TO PREVENT WHEYING OFF    
WHY IS CARRAGEENAN ADDED TO ICE CREAM?    
TO HELP PREVENT SHRINKAGE    
SUGGESTED MIXER FOR HARD-FROZEN ICE CREAM    
ICE CREAM/FROZEN DESSERT MARKET IN INDIA    
MANUFACTURING PROCESS    
ICE CREAM STABILIZER COMPOSITION    
FORMULATION - 1    
OTHER FORMULATION - 2    
FACTORS FOR GOOD ICE CREAM PRODUCTS.    
CHEMICALS:    
PROCESS FLOW SHEET    
ICE CREAM AND ITS INGREDIENTS    
GENERAL ICE CREAM PROCESSING STEP    
1. BLEND THE ICE CREAM MIXTURE    
2. PASTEURIZE MIX    
3. HOMOGENIZE    
4. AGE THE MIX    
5. ADD LIQUID FLAVORS AND COLORS    
6. FREEZE    
7. ADD FRUITS, NUTS AND BULKY FLAVORINGS (CANDY PIECES, ETC.)    
8. PACKAGE    
9. HARDEN    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
PRIMARY FACTORS    
1.   RAW-MATERIAL SUPPLY:    
2.   MARKETS:    
3.   POWER AND FUEL SUPPLY:    
4.   WATER SUPPLY:    
5.   CLIMATE:    
6.   TRANSPORTATION:    
7.   WASTE DISPOSAL:    
8.   LABOR:    
9.   REGULATORY LAWS:    
10.  TAXES:    
11.  SITE CHARACTERISTICS:    
12.  COMMUNITY FACTORS:    
13.  VULNERABILITY TO WARTIME ATTACK:    
14.  FLOOD AND FIRE CONTROL:    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
1. DEPRECIATION:    
2. FIXED ASSETS:    
3. WORKING CAPITAL:    
4. BREAK-EVEN POINT:    
5. OTHER FIXED EXPENSES:    
6. MARGIN MONEY:    
7. TERM LOANS:    
8. TOTAL LOAD:    
9.   LAND AREA/MAN POWER RATIO:    
PROJECT IMPLEMENTATION SCHEDULES    
INTRODUCTION    
PROJECT HANDLING    
PROJECT SCHEDULING    
PROJECT CONSTRUCTION SCHEDULE    
TIME SCHEDULE    
SUPPLIERS OF RAW MATERIALS    
CARBOXY METHYL CELLULOSE (CMC)    
LAMINATED BAGS    
SUPPLIERS OF PLANT AND MACHINERY    
PULVERIZERS    
DEHUMIDIFIER    
PACKAGING MACHINE    
LABORATORY EQUIPMENTS


APPENDIX – A:

01.    PLANT ECONOMICS    
02.    LAND & BUILDING     
03.    PLANT AND MACHINERY    
04.    OTHER FIXED ASSESTS    
05.    FIXED CAPITAL    
06.    RAW MATERIAL    
07.    SALARY AND WAGES    
08.    UTILITIES AND OVERHEADS    
09.    TOTAL WORKING CAPITAL    
10.    TOTAL CAPITAL INVESTMENT    
11.    COST OF PRODUCTION    
12.    TURN OVER/ANNUM    
13.    BREAK EVEN POINT     
14.    RESOURCES FOR FINANCE    
15.    INSTALMENT PAYABLE IN 5 YEARS    
16.    DEPRECIATION CHART FOR 5 YEARS    
17.    PROFIT ANALYSIS FOR 5 YEARS    
18.    PROJECTED BALANCE SHEET FOR (5 YEARS)