OBJECTIVE: The purpose of this report is to provide background information identifying potential hazards within the specialist manufacture

of ice cream. this report sheds light on the types if risk(loss exposure) that are present during the large-scale manufacture of ice cream. In order to learn about the different aspects of this report, I had visited the Neerala-Ice-Cream Factory INDUSTRY PROFILE: The Neerala ice cream was formerly know as Nirula,which was a popular fast food joint under the Food Court Pvt Ltd.But due to the internal management problems, it had to be shut down.Neerala is trying to build on the goodwill of Nirula.The company operates as a fast food joint. It currently has 12 flavors of ice cream. Its sells an average 500 liters of ice cream a day. Out of its 12 flavors Blind love, vanilla and chocolate blast are the most popular. This report describes the manufacturing process and identifies the risks present in the industry.

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INTRODUCTION: Ice cream is a frozen dessert usually made from dairy products, such as milk and cream, combined with fruits or other ingredients and flavors. Most varieties contain sugar, although some are made with other sweeteners. In some cases, artificial flavorings and colorings are used in addition to (or in replacement of) the natural ingredients. This mixture is stirred slowly while cooling to prevent large ice crystals from forming; the result is a smoothly textured ice cream Products of dairy origin are the main ingredients of ice cream. These include whole milk, skimmed milk, cream, frozen cream, condensed milk products and milk solid. Other ingredients include flavoring matters and water. Fruits, nuts, candies and syrups are optionally added into ice cream for flavor enrichment. Two types of ice cream, soft and hard, are available on the market. HISTORY: The origins of ice cream can be traced back to at least the 4th century B.C. Early references include the Roman emperor Nero (A.D. 37-68) who ordered ice to be brought from the mountains and combined with fruit toppings, and King Tang (A.D. 618-97) of Shang, China who had a method of creating ice and milk concoctions. Ice cream was likely brought from China back to Europe. Over time, recipes for ices, sherbets, and milk ices evolved and served in the fashionable Italian and French royal courts. After the dessert was imported to the United States, several famous Americans served it. George Washington and Thomas Jefferson served it to their guests. In 1700, Governor Bladen of Maryland was recorded as having served it to his guests. In 1774, a London caterer named Philip Lenzi announced in a New York newspaper that he would be offering for sale various confections, including ice cream. Dolly Madison served it in 1812. Jacob Fussell established the first commercial ice cream plant in Baltimore in 1851.

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STEPS IN THE MANUFACTURE OF ICE CREAM: The Large-scale production/manufacture of ice cream is a complex procedure and as observed in the Factory the production process can be broadly divided into the following stages: 1. Ice cream mixing: This step broadly involves mixing of ingredients, pasteurization and homogenization. 2. Soft ice cream production: Soft ice cream production involves ageing and freezing the mixture 3. Hard ice cream production: This step involves the Packaging, hardening and storage of the ice cream. The manufacturing of ice-cream mix involves mixing of ingredients, pasteurization and homogenization. For soft ice cream, pre-made ice-cream mix is supplied to the retail outlets under refrigeration (< 7C). Aging and freezing at around -5C are performed in the vending machines at the retail level. Other ingredients, such as fruits and nuts, may be added to the soft ice cream at the time of sale for flavor enrichment. In frozen confection factories, the soft ice cream will be packed and hardened to produce the hard ice cream. The following paragraphs describe the technological details of each processing step.

1. Mixing of ingredients The first step of preparing ice-cream mix is to combine the liquid Ingredients(includes milk, milk solids and cream) and heat them to around 30C to 75C . Then, sugar and other dry ingredients, except nuts and fruits, are added to the lukewarm mix.

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Ice-Creammixingplant 2. Pasteurization The mixture is then pasteurized by a heating process, either in batch or continuous modes, depending on the production size. Pasteurization temperatures for ice-cream mix, around 70C for 10 30 minutes , are higher than that for plain milk because high fat and sugar contents tend to protect bacteria from heat treatment.

PasteurizationVessel

3. Homogenization The pasteurized mix is then homogenized. High pressures of 4.1 x 106 Pa (600 psi) to 1.7 x 107 Pa (2500 psi) are used to break down fat globules This pressure can clump fat QuickTime and a globules and, together with the TIFF (Uncompressed) decompressor are needed to see this picture. added emulsifiers, can prevent churning of fat into butter granules (milk fat) during freezing step. Homogenization also improves the texture of ice cream. In other words, the ice cream becomes smoother. After that, the homogenized mix is cooled down to 4C for further processing. Homogenizer 4. Ageing Aging is the first step in soft ice-cream production. The mix is held in sterilized vats from 3-24 hours at temperature of around 4C or lower. It allows some physical changes, such as fat crystallization, adsorption of protein onto fat globules, and incensement of the mixs viscosity. These changes lead to quicker whipping to the desired overrun1 in freezing process, smoother ice-cream body and texture, and slower ice cream meltdown.

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AgeingVat Ice Creammachine 5. Freezing During freezing, air is incorporated in the mix and cooled down to around -5C. Freezing must be performed as quickly as possible to prevent the formation of large ice crystals. The air cells in ice cream should be small and evenly distributed in order to maintain a stable frozen foam. At this low temperature, -5C, not all water

particles are crystallized and, therefore, ice cream is only in semisolid state. The semisolid ice cream emerging from the freezer is similar to the constituency of soft ice cream produced at the retail level. Other ingredients, like fruits, nuts, or syrup, may then be added to enrich the flavor of ice cream.

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Compact Refrigeration System 6. Packaging To produce hard ice cream, the semisolid ice-cream is packed into cartons or drums for hardening process to form specific shape of ice-cream products and to have longer shelf-life (more than one year).

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7. Hardening The pre-packed semisolid ice cream is then placed in a hardening room where the temperature of about -34C is maintained. This low temperature keeps the core temperature of ice cream at around -18C. Hardening should be better quality of ice cream..

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Ice cream hardening Cabinet 8. Storage After hardening, the hard ice-cream will then be placed back in the cold store rooms with temperature of around -18C. From this stage, the hard ice cream must be kept at -18C or below throughout storage, transportation and display.

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Ice cream storage Cubicle

HAZARDS ASSOCIATED WITH THE MANUFACTURING OF ICE CREAM: On the basis of my survey of the Manufacturing area and the information provided by the employee. The most relevant risk faced by the ice cream manufacturer is the Liability Risk, as carelessness in the manufacturing can cause food poisoning. Food poisoning is an unpleasant illness. For young children, pregnant women, the elderly and the sick, it can be serious and sometimes fatal. Typical symptoms of food poisoning include: Nausea/vomiting Diarrhoea Stomach pains Headaches. The food poisoning is caused by the pathogens and other substances that are inherently or can be mistakenly contaminated present in the ice cream And if the healths of consumers are threatened, this can pose a great risk of CONSUMER LIABILITY to the producer. The risk hazards can be classified into 3 types: 1. Micro-Biological 2. Chemical 3. Physical 1.MICROBIOLOGICAL HAZARD: This kind of hazard is the presence of pathogens in the raw material and the finished ice cream. As we know milk and milk products are the main ingredient of milk and if milk if not treated well can cause a wide range illnesses. There are various kinds of microbial hazards present in the various stages of the manufacturing process o Raw Material The raw materials of ice cream are milk, skimmed milk, condensed milk, milksolids and in some cases eggs, And if these products especially egg are not treated well can cause severe food poisoning illness like salmonella etc. Hazard: Presence of pathogens that can cause food poisoning. Control-Measure: Purchase of materials from reputable suppliers Intake testing of milk

o Pasteurization: This step is basically involved with the treatment of milk. Hazard: Presence of pathogens Control-Measure: Correct time and temperature control Maintained of equipment Effective and regular disinfection of equipment. o Ageing: In this step the ice cream mixture is kept in sterilized vats. Hazards: Recontamination after effective pasteurization. Control-Measure: Cleaning and disinfecting the vats Temperature has to be obtained at below 5oC . o Ingredient addition: This step is when the dry ingredients like nuts syrups and flavorings are added. if these materials are contaminated it can contaminate the whole ice cream mix. Hazards: Contamination Control-Measure: Maintaince of hygiene of manufacture area Purchasing of material from reputable suppliers Refrain from using expired products. o Storage and Transportation: Hazard: Growth of harmful microorganisms. Control-Measure: Temperature has to be maintained < 18oC. Discard the products once melted. Maintaince of < 18oC temperature in the transportation vans.

2.CHEMICAL HAZARD: Toxic substances and any other compound that may render a food unsafe for consumption to the general public. e.g. bleach in ice cream. Hazard: Residue of cleaning agents in the equipment Spilling of hazardous material Control-measure: Ensuring no residue is left behind. Proper storage of hazardous material. 3.PHYSICAL HAZARD: Physical hazard are materials present in the ice cream that can cause severe damage if consumed. e.g:Fragments of glass in mixture Physical hazards can occur intentionally or unintentionally. Hazard This is risk due to foreign materials glass, metal, plastic paper, hair, steel bolt insects etc Control Measure: Through examination of finished products. Installed quality checkers. OTHER SAFETY MEASURES ADOPTED: 1. Installed fire extinguishers and fire safety devices as to manage fire risk. This is an example of minimizing the severity of loss. 2. The surfaces of the floor below equipment require to be cleaned. 3. The surfaces of the floor and ceiling of the freezer require to be cleaned and build up of ice removed 4. Every person working in ice cream manufacturing area requires to wear clean protective clothing 5. Person operating the equipment must have adequate training. 6. Waste should be disposed effectively and management.

DUE TO THE COMPANY POLICIES THE INFORMATION ON THE INSURANCE DETAILS COULD NOT BE DISCLOSED .However the following policies are recommended:

1. Fire Insurance policy: A fire insurance policy is highly recommended as equipments operating at high temperature and at high pressure and the building should also be equipped with fire escapes. 2. The next policy recommended is Worker Compensation or worker insurance, as any hazard can occur while the operation of the equipments. 3. The third and final policy recommended is the insurance of the property i.e. the equipment, which is the foundation of industry.