Yummy ! How Ice Cream is Made

Smarty Spark

#icecream #IceCream #food #sweet #factory

Transcript

00:00Ancient Greeks, Romans, and Jews were known to chill wines and juices as a treat during the summer months.

00:06This practice evolved into fruit ices and, eventually, frozen milk and cream mixtures.

00:11But it wasn't until the 20th century that ice cream became available to the common man.

00:17As the Industrial Revolution brought electric power, steam power, and mechanical refrigeration,

00:22the ice cream market grew to astronomical size, with an estimated market size of 81.8 billion U.S. dollars in just the United States.

00:32So how is it made?

00:34The process begins with cream, which arrives at the factory in refrigerated trucks and is then stored in refrigerated silos,

00:42kept at a constant 4 degrees Celsius.

00:45Because cream is a dairy product, it carries a high risk of contamination through bacteria,

00:50keeping it at a lower temperature during transport and storage helps maintain its freshness and quality.

00:56The silos feed a high-speed mixer that mixes the cream with other ingredients.

01:01The main dry ingredients are powdered skim milk and plant-based stabilizers and emulsifiers.

01:07Stabilizers prevent the ice cream from crystallizing and emulsifiers allow the mix to bond with air during the whipping process.

01:15The other ingredients are sugar and corn syrup.

01:17After about three minutes of mixing, a pumping system moves the mixture into specialized pasteurization machines.

01:24The most commonly used machine is called a plate heat exchanger.

01:28It consists of a series of stainless steel plates that are pressed together with gaskets,

01:33creating channels for the mixture to flow through.

01:36The plates have a large surface area, allowing for efficient heat transfer.

01:40During pasteurization, the mixture is pumped into one side of the plate heat exchanger,

01:45while hot water or steam is circulated on the other side.

01:49The heat from the hot water or steam is transferred to the mixture through the plates,

01:54effectively heating it to the desired pasteurization temperature.

01:58The tanks keep the mixture at 72 degrees Celsius for half an hour,

02:02killing any bacteria and activating the stabilizers.

02:05Then, the factory homogenizes the mixtures, a process that breaks up the fat globules,

02:11giving the ice cream a smooth texture.

02:14During homogenization, the hot mix is forced through small openings at high pressure

02:19to reduce the liquid fat droplets to a small, uniform size.

02:23Homogenization is integral to ice cream's smooth texture

02:26and prevents fats from churning in the later freezing stage.

02:30After homogenization, the base mixture is often aged for a certain period,

02:35typically several hours to overnight in refrigeration.

02:39This allows the flavors to meld and the texture to stabilize.

02:43The base mixture is cooled down to a lower temperature,

02:47usually around 4 degrees Celsius, 39 degrees Fahrenheit.

02:51Chilling helps reduce the freezing time and ensures a smoother freezing process.

02:55The chilled base mixture is transferred to an ice cream machine,

02:59which is a continuous freezer.

03:01The machine freezes the mixture while simultaneously churning it.

03:05The churning incorporates air into the mixture,

03:08increasing its volume and creating a lighter texture.

03:11In fact, the volume of the ice cream can increase by 60 to 100%

03:15simply because air is added.

03:17The incorporation of air is crucial.

03:20It makes the ice cream softer and slows the melting process.

03:24Without air, ice cream would be too hard to eat.

03:26The temperature inside the machine is set between

03:29negative 5 to negative 8 degrees Celsius, 23 to 18 degrees Fahrenheit.

03:35During the freezing process, additional ingredients such as chocolate chips,

03:39nuts, cookie dough or fruit pieces can be added.

03:43These ingredients are typically added through specific openings in the machine,

03:47ensuring even distribution throughout the ice cream.

03:50Automatic filling machines drop pre-printed pint or half-gallon-sized cardboard cartons into holders.

03:57The cartons are then filled with pre-measured amounts of ice cream

04:00at the rate of 70 to 90 cartons per hour.

04:03The machine then places a lid on each carton and pushes it onto a conveyor belt.

04:08The cartons move along the conveyor belt, where they pass under an inkjet

04:12that spray paints an expiration date and production code onto each carton.

04:17After the imprinting, the cartons move through the bundler,

04:20a heat tunnel that covers each cup with plastic shrink wrapping.

04:23The packaged ice cream is moved to a blast freezer,

04:26where it is rapidly frozen at temperatures below negative 18 degrees Celsius, 0 degrees Fahrenheit.

04:32This freezing process helps maintain the texture, quality and shelf life of the ice cream.

04:38It's then transported and stored in supermarket freezers or ice cream shops

04:43until it's purchased by customers.

04:45I don't know about you, but ice cream is my favorite sugary treat.

04:49And if you are wondering how sugar is made, check out this video.

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