TECHNOLOGY

With the quality using in manufacturing Ice Creams and with latest production technology we are using, we had got the tender for supplying 500ml ice creams to the World famous temple and pilgrimage center, Tirumala Tirupati Devastanam's SV Canteen for the year 2005. For this contract several ice cream manufacturing companies had submitted tenders. TTD (Tirumala Tirupati Devastanam) had conducted lab tests for the Ice Creams manufactured by these companies and finally they had approved that that the Joy Ice Creams manufactured by Thrupthi Frozen Foods are highly qualitative.

The basic steps we are following in the manufacturing of ice cream are generally as follows:

blending of the mix ingredients
pasteurization
homogenization
aging the mix
freezing
packaging
hardening

Blending of the mix ingredients:

Blending requires rapid agitation to incorporate powders, and often we use high speed blenders .

Pasteurization :

The mix is then Pasteurized. Pasteurization is the biological control point in the system, designed for the destruction of pathogenic bacteria. In addition to this very important function, pasteurization also reduces the number of spoilage organisms such as psychrotrophs, and helps to hydrate some of the components (proteins, stabilizers).

Homogenization:

The mix is also homogenized which forms the fat emulsion by breaking down or reducing the size of the fat globules found in milk or cream to less than 1 µ m. We use two stage homogenization for ice cream mix. Clumping or clustering of the fat is reduced thereby producing a thinner, more rapidly whipped mix. Melt-down is also improved.

Ageing

: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.

Freezing

Following mix processing, We use dynamic freezing process which both freezes a portion of the water and whips air into the frozen mix.

Hardening:

the ice cream is packaged and we placed it into a blast freezer at -30° to -40° C where most of the remainder of the water is frozen. Below about -25° C, ice cream is stable for indefinite periods without danger of ice crystal growth.

Equipment and systems involved in the process include:

Sieves with metal separators.
Blenders for efficient and uniform mixing.
Thermal fluid systems for indirect, clean and pollution – free heating.
Automatic product filling systems.
Form-fill-and-sealing machines for packaging and employment of metal detectors.
Material handling systems like hydraulic trolleys, elevators, etc.
Another salient feature of the manufacturing process is the Product Traceability System (PTS), which makes use of various online data logging records arranged according to the Batch No. on the final packing. The system enables traceability of the product back to the Batch and the individual ingredients that form part and parcel of the products manufactured in the particular batch.