Ice cream plant synopsis
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Land required- 10-12 katha. (10*720 sq ft).
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Shed required- 4000 sq ft.
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Production capacity- 600 lit/hr, 6000-8000 lit/day.
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Profit margin- 16-18 rs/lit (including labour and electricity).
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Project cost- 1.25/2.50 cr.
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Cost of plant and machinery- 35 lacs to /1.75 cr depending on automation.
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Complete selling arrangement. Brand can only be decided after MOU. If the project volume is higher. Else assistance for selling.
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Liquid capital required for entrepreneur’s contribution (margin money for bank) 15 lacs if shed is present or it would be 25- 30 lacs.
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Net profit- 6-18 lacs per month. ( after labour, electricity and repayment of bank loan).
TECHNICAL APPRAISAL
MANUFACTURING PROCESSES
Ice-cream is readily and easily available in a variety of forms such as chocolate-dipped bars and in sandwiches form too. Ice cream is part of food that is loved by everyone. The manufacturing process of ice cream comprises of ten steps that includes:
i. Raw materials delivery & storage
ii. Blending the mixture
iii. Pasteurizing
iv. Homogenizing
v. Cooling
vi. Adding flavors
vii. Continuous freezing
viii. Adding extra fruits and chunks
ix. Packaging
x. Hardening
RAW MATERIALS DELIVERY & STORAGE
The first step is to arrange for the raw materials and store them at the suitable and perfect environment in order to protect them from any danger.
BLENDING THE MIXTURE
The milk will arrives at the ice cream factory in the refrigerated tanker trucks from the local dairy farms. The milk will be then pumped into 5,000 gal (18,925 1) storage silos that will be kept at the temperature of around 36°F (2°C). Pipes will be used in order to bring the milk in the pre-measured amounts to around 1,000 gal (3,7851) stainless steel blenders. Premeasured and quantified amounts of eggs, sugar, and other additions are then further blended with the addition of milk for around eight to ten minutes.
PASTEURIZING
Pasteurizing is a process which will be done in order to kill the bacteria. The mixture, which will be blended, will be then piped to the pasteurization machine, which is made up of a thin stainless steel plates. Hot water of around 182°F (83°C) flows on the one side of the plates. On the other side, the cold milk mixture will be piped from the other side. The water will warm the mixture to the temperature of around 180°F (82°C), this process will thus helps in killing bacteria. HOMOGENIZING
With the input of an intensive air pressure, sometimes as much as 2,000 pounds per square inch (141 kg per sq cm), the hot mixture will be forced with the help of a small opening into the homogenizer. This will eventually, breaks down the fat particles and will prevent them from separating from the rest of the mixture. Homogenizer is one of the high-pressure piston pumps; therefore the mixture is further blended as it is drawn into the pump cylinder on the down stroke and then forced back out on the upstroke.
COOLING
The mixture after the process of homogenizing will be then piped back to the pasteurizer where the cold water at approximately 34°F (1°C), will flows on one side of the plates and at the same time, the mixture passes on the opposite side. In this manner, the mixture is thus cooled to 36°F (2° C). Then the mixture is pumped to 5,000 gal (18,925 1) tanks in a room set at 36°F (2°C), where it sits for around four to eight hours to allow the ingredients to blend. ADDING FLAVORS
The ice cream is then pumped to a stainless steel vats, each stainless steel vats will be holding up to 300 gal (1,136 1) of mixture. Flavorings are then piped into the vats and will be blended thoroughly CONTINUOUS FREEZING
Now the mixture will be frozen. It is pumped into the continuous freezers that can freeze up to 700 gal (2,650 1) per hour. The temperature inside the freezers is kept at -40°F (-40°C), liquid ammonia will be using 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 FRUITS AND CHUNKS
If chunks of food such as strawberry or cookie pieces are to be added to the ice cream, the frozen mixture is pumped to a fruit feeder. The chunks are loaded into a hopper at the top of the feeder. Another, smaller hopper, fitted with a star wheel, is located on the front of the feeder. An auger on the bottom of the machine turns the hoppers so that the chunks drop onto the star wheel in pre-measured amounts. As the mixture passes through the feeder, the 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 half-gallon-sized cardboard cartons into holders. The cartons are then filled with premeasured amounts of ice cream at the rate of 70-90 cartons per hour. The machine then places a lid on each carton and pushes it onto a conveyer belt. The cartons move along the conveyer belt where they pass under an ink jet that spray-paints an expiration date and production code onto each carton. After the imprinting, the cartons move through the bundler, a heat tunnel that covers each cup with plastic shrink wrapping.
HARDENING
9 Before storage and shipping, the ice cream must be hardened to a temperature of -10°F (-23°C). The conveyer system moves the ice cream cartons to a tunnel set at -30°F (-34°C). Constantly turning ceiling fans create a wind chill of -60°F (-5 1°C). The cartons move slowly back and forth through the tunnel for two to three hours until the contents are rock solid. The cartons are then stored in refrigerated warehouses until they are shipped to retail outlets.
RAW MATERIALS USED
Raw materials required to manufacture ice cream varies from ice cream to ice cream, main ingredients like milk, butter, sugar remains there but other ingredients are also mixed to make different types of ice creams, following mentioned are some ingredients to produce ice cream;
Milk:
Milk is the main ingredient in production of ice cream and fluctuation in its price and availability directly affects Ice cream’s price and production, Pakistan is the 4th largest milk producing country in the world, Pakistan produces 33million liters of milk annually. Pakistan is not only exporting milk but its products too. Pakistan has 50 million animals that is huge quantity but most of the farmers don’t want to connect with the formal markets and this is the reason they don’t play significantly in economic growth of the country.
Butter:
This is also related to milk, butter can be formed after processing of milk, and its consumption in ice cream depends upon the type of ice cream if it is kulfa or some other creamy ice cream than it will be used in large quantity.
Sugar:
Sugar is used to make ice cream sweet; it is used in all types of ice cream, nowadays its increased prices and shortage causing trouble in ice cream production, it is 2nd most important crop in Pakistan, Pakistan grows about 1 million hectares of sugarcane, more than all other cane producing countries except Brazil, China, Cuba, India and Thailand.
Dry Fruits:
In some ice creams like “KULFA” dry fruits are used including almond, pista, this is also very famous in rural areas of the country.
Flavor:
Food flavors are used in this all the flavors are easily available in the market and there is no hurdle to get those flavors. ICE CREAM FACTORY Institute Of Business Management Page 17
Fruit Pulps:
As ice creams are in different flavors and sometimes they are in flavor of different fruits, for this they need pulp of that fruit too. E.g. to produce mango ice cream, mango pulp is required.
Cones:
For ice cream cone there is a need of cone with the ice cream, three main dry ingredients compose all types of cones. Wheat flour, tapioca flour and sugar are chosen for baking quality, strength and sweetness respectively.
EQUIPMENTS
The machineries / equipments used in manufacturing of ice cream are listed below.
• Mixing units
• Storage units
• Homogenizer
• Extrusion ice cream machines
• Moulding ice cream machines
• Filling ice cream machine
• Hardening ice cream machines
• Ice cream packaging machines
• Hardening ice cream machines
• Ice cream freezing machines
• Choko bar hardner
• Chocolate pot
• Ice cream churner
• Ice cream ageing machine
• Brine tank
• Surface cooler
• Filling and Packaging line