Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man MUC LUC LTONG QUAT VE KEM * Gidi thigu chung © Neuyén ligu TL.QUY TRINH SAN XUAT ¢ Gidi thich quy trinh céng nghé - 1. Chudin bi nguyén ligu - 2. Ph6i tron~ 3. Déng hod 4, Thanh tring 5. U chin 6. Lanh dong so b6 UL.GIGI THIEU THIET BI 1 Thiét bi tanh dong 2 Thiét bj to hink, lam ettng 3. Thiét bi tg0 vé 4o chocolate IV.SAN PHAM. Y.TAI LIEU THAM KHAO Lép HCO4TP Trang 1Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man 1. TONG QUAN VE KEM GIGLTHIEU CHUNG Ngay nay, kem I mt sin phim duge tiéu thy rong rai 6 moi quée gia, va thu hut ngudi tiéu ding 6 moi lita tuéi khée nhau, nhung it ngudi biét ring kem c6 mot lich sit kh lau di, Kem an xudt hign @ thé ky thi’ 4 trutée cong nguyén, 3 cdc quée gia nhut La Ma, Trung Hoa phye vy cho vua chtia bing cach lay da lanh trén cdc dinh nti cao vé tron vi cc logi trai cay hode sita tao thanh mén “kem”, ‘Theo truyén thuyét thi Marco Polo da mang bf quyét ché bién kem tir Trung Quéc vé MY, sau nay nguei MY da bién viéc sdn xudt kem thanh mot nén céng nghé ché bién phat trién manh mé. Nam 1946, b& Nancy Johnson ngudi New York da phat minh ra m@1 loai tf anh chuyén ding dé chita kem, may am kem ngdy nay duye mang tén “Johnson Patent Ice-Cream Freezer”. Nam 1962, cng nghé lam kem thuong mai ln dau tién duge cap bing sing ché. Cang véi thdi gian, nganh sin xut kem phat trién manh mé cho ra di nhiéu ddng sin phdm: kem hOp, kem ly, kem chocolate, kem tréi cdy, kem vani, kem cometo... kem td thinh m6n an tang migng ua thich ca cd wé em Kin ngudi Ién. ‘Theo théng ké ctia Hiép hoi kem An thé gigi, loai Kem phé bién nhét [a kem vani- 29%, ké dén 1 kem chocolate-8.9%, kem hat dé va kem dau-5.3%, kem (ng hgp- 4.2%, kem boc chocolate-3.9%, kem vanola kiéu Phép-3.8%. Theo s6 ligu cia Higp h6i cde nha sn xudt sf va cdc sin phim ti sita, My Ia quéc gia sin xudt kem &n I6n nhat thé gidi vdi 61.3 triéu hectolit/nam, ké dén 1a Trung Quée 23.6 trigu hectolivnam. Tuy nhién, New Zealand Iai f& nude tiéu thy kem manh mé nhat thé gidi vdi 26,3 trigu hectolit/nim, ké dén Ia My 22.5 triéu hectolivnam, Trung binh, mot ngu®i New Zealand sit dung 26.3 lit kem/ndm, trong khi 46 mite tiéu thy kem cila ngudi Trung Quée [a 1.8livnm, Mite tiéu thy kem trung binh ctia nguti Vigt Nam [2 0.3 Titv/nam. + NGUYEN LIEU TRONG SAN XUAT KEM 1) Sia va cdc sin phim tif sifaz Tao nén gid tr dinh duOng va hudng vi cho kem. Sita dung cho sin xudt kem e6 thé Ja sia tuoi, sita b6t nguyén cream, sia bot gay, chat béo tif sifa nhu cream, bd, hay chat béo khan... Yéu cu quan trong déi vai sifa lam kem Ia phii c6 ham Iwgng chit béo cao, lugng chit béo trong sita 1a yéu t6 gitip tao nén cfu tric dic trung ciia sin phim. 2) Dutmg: Duding gitip tao vi ngot, higu chinh ham lugng chat kho, tang gid tri dinh duong va g6p phn tao cfu tnic sin phim, Ngoai dung lactose c6 siin trong sifa, thuting sit dung duding saccharose, dung nghich dio va syrup gidu fructose. 6 Mj va Chau Au con sit dung cht ngot nghéo gid tri dinh dung nhut sorbitol, aspartam, polydextrose... dé sin xudt kem phyc vy cho ngudti bj tiéu dudng hay béo phi Lép HCO4TP Trang 2Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man 3) Chit béo: Chat béo 1 thanh phan chi yéu tham gia vao cu tric cila kem, 06 thé sit dung dau thy vat nhu dau nanh, dau cdi, diu dita hay dau huéng ditong két hgp véi chat béo eda stta dé sin xufi kem. Ham luong dau thye vat e6 thé chiém 6-10% kh6i lugng kem thanh phim, 4) Chat nhii hé: Chat nhil héa cé vai tro ting kha ning lién két gitfa cfc hat cdu béo, digu nay quyét dinh I6n dén kha nang gitt nude cia kem, Trong san xudt kem c6 thé si dung chat nha héa thong dyng nhur long dé tring nhung gié thanh thudng khé cao, ngdai ra c6 cfc loai chat ni héa khéc ré tién hin nhvf mono hay diglyceride, céc ester cia sorbitol hay cia cdc phan ti dvdng.. 5) Chat 6n dinh: dinh tgo ra mang Iti khOng gian dé han ché sit chuyén dong ty do cla cde phan tit nude, nh 46 tong qué trinh lanh dong hn hgp nguyén ligu dé sin xudt kem, cdc tinh thé dé xudt hién sé 06 kich thude nhé, kem iré nén dng nha. Chat én dinh ding cho sin xudt kem thuéng co ban chét protein nhu gelatin, casein, albumin, globuline... hay carbohydrate nhut agar-agar, gum arabic, CMC (carboxymethylcellulose). 6) Chit tgo huang: Hung ligu cing vdi sif tgo hinh kem igo ra stf da dang cho sin phim kem. Céc Joai hung ligu thudng sit dung nbvf vanilla, mdi cam, mii sdu ri€ng, du, chocolate, mii cd phé... Chiing dude trich ly tir thye vat hoe duge sin xuat bing phuong phép tng hgp héa hoc. Ngoai ra, trong san xudt kem, ngu@i ta cling cé thé bé sung thit qua cét hd, c&c logi hat (hd dao, hanh nhdn, phi, hach, hé trin, d3u phong, diéu..), bot cacao, dich chocolate... Nhiing nguyén ligu trén ngoai muc dich tgo hudng cdn gidp ting gid tr} dinh duOng cho kem thanh phim. 7) Chat man Mau sfc tao sy 16i cuén hap din cho kem tit c4i nhin dau tién. Cac nhém sin phéim cin tao mau 1a cc sin phdm kem c6 huong vi tri cay. Kem c6 huong vi tri cay nao thi cn e6 mau cia loai tréi cay dy, vi du niu kem nho edn c6 mau nau dé, kem sdu riéng c6 mau ving... Nhém chat mau tf nhién c6 dO bén mau kém han so vai chat mau tng hgp tcong diéu kign sin xudt cOng nghiép. Viée sit dung chit mu twan theo quy dinh sit dung phu gia 6 mdi quéc gia. 8) Nguyén ligu khde: = Nu@e va khéng khi: Nuéc cé téc dung tao tinh thé da, tao dé cifng cin thiét va tao cim gidc mat lanh hi sit dung sin phém. Kh6ng khi gitip cho san phdm c6 d6 mém, xép. Lép HCO4TP Trang 3Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man I. Quy Lép HCO4TP Acid: vige bd sung acid hdu oo nh acid citric, acid tartric.ngodi vie wo 49 chua thich hyp cho kem, cdn c6 tic dung te ché sy phat trién cia mot 86 vi sinh vat cd trong sin phém. Phy gia chéng vi sinh vat: thudng st dung natri benzoat, tuy nhién nhiéu nufde trén thé gidi khong cho phép sit dung phy gia nay. Tinh bot: wong cong thifc kem cia nhiéu nude trén thé gidi thudng khong sit dung, nhung céc nha sin xuft kem ciia Vit Nam thuding stt dung tinh bot binh thuing hay tinh bot bién tinh nhlim myc dich gia ting dO két dink cia khdi kem. TRINH CONG NGHE Trang 4Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viet Min Nguyen ligu chinh: ‘Sia, cream, bot sta shy, syrup duting ‘Nguyen ligu phu: cht qo abi, chit da inh mau. mdi. Chun bi > [Phot won ]<{_Chudn bi V Béng hoa Thanh tring, Uehin V Lanh dong so bo Hép hy >—> [_RothGphy Bé khudn y V (Lanh sort két thus Lanh Uudiém: ~ Phuong phip t6t nhat dé 1am sin phim dang que = Thdi gian luv git sin phdm ngdn nhae ~ T6c do san xuat nhanh vai mite d6 ty dong héa cao - Chit lugng san phi ~ Qué winh truyén nbiét hiéu qui cao > Nhuge diém ~ Qui trinh hé thong don 1é = Yéu ciu khu vue sin xudit tin kém ~ Yéu ciu thiét bi phai dim bao vé sinh ~ MOt vai bo phan thiét bj thi nude thira nhiéu - Sv hao hut sin pham trong qu trinh sin xuat tudng déi cao ~ Chi phi cho tiing b6 phn sin xu cao cao Lép HCO4TP Trang 20Quy tinh va thiét bj sin xuait kem GVHD: Thay Lé Van Viet Man Hin 12: thiét bi fam eng bing phyong php nhiing chim ¢) Lam cing trong kun: > Uudiém ~ Sin xudit sin phdim c6 dang hinh vudng hay hinh chi nhat = Thdi gian luv gitt sin phdm ngdin nha = Qué trinh truyén nbiét higu qué - Yéu ciu kho’ing khong gian nhd véi chi phi sin xudt it tn kém ~ Sutén that trong qua trinh [am cing rit it > Nhuge diém: - Khodng 5% sin phém cé hinh dang khong déng déu - Tén chi phi cho nhiing sin phém khéng duge lam cing. - Sin phim bi anh hudng khi khong duge rot diy ~ Yeu cdu nhigt do lam déng théip Hinh 13: thiét bi lam ctfng dang tim (plate) Lap HCoaTP Trang 21Quy tinh va thiét bj sin xuait kem GVHD: Thay Lé Van Viet Man @) Lam cifng trong pallet véi ludng khong khi lanh: > Undiém: - Dan gidn vé may méc so voi cée phutong phép d6i liu khong khi khée = Diu wr chi phi thap ~ Kich thie bao g6i da dang = Chi phi bio duong may thap » Nhuge diém: = Higu qui fam cing thap - Yéu cau theo doi nghiém ngat dé dim bao chat lugng sin phim ~ Chi phi nhan cong cao = Suhao hut sin phim cao Hinh dang dng g6i khong dep Ml I ee ~ i i u , ] | J ww Hinh 14 : Thiét bi lam ting trong pallet vdi ludng khong khi lanh. e) Lam citing bing day chuyén xodn 6c: >» Uudiém: — May méc dan gin hon so véi phuong phap doi luu khOng khi ty dong = khie ~ Higu qua’ fam cing cao voi cdc théng s6 cdi tude ~ Dau uf v6n tir thap ti vita phai - Lam cting déng thdi céc sin phim c6 kich cd khéc nhau = Sy hao hut sin phim thap ~ Kich thie c6 sin trong hé théng tit 250GPH > Nhuge diém: — Day dai ché sin pham gidi han 101bs/ft Lap HCoaTP Trang 22Quy tinh va thiét bj sin xuait kem GVHD: Thay Lé Van Viet Man = Quat sir dung yéu clu nang lwng cao = Khé khan trong qué trinh dng g6i ty dong khi nang suat cao Tr faith ue Hinh 15: thiét bi kam tng bling diy chuyén xoiin Ge. f) Lam cting bling phudng phip sit dung ede khay gidta chudi lién tue (Tray between continuos chain): > Undid = Thiét bi don gidn nhét so v6i thiét bj Iam ettng bing phuong phdp lam citing bang d6i lwu khong khi sin phdm loai khay = Sutdi chuyén dong d6i gisip qué trinh lam eitg hiéu qui hon = Chi phi dau wr vita phai = Lam ctfng déng thii ede sin phd kich thyve khée nhau — Sv tén that trong qua trinh lam eting rat it ~ HE théng khong khi hogt dong higu qua nén tiét kiém nang hrgng va idm chi phi - He thong nhé 250GPH > Nhuge diém: = Toe d6 vat ligu:2500GPH ~ Khong thich hgp cho sin xusit déng thoi nhiu day chu = Chi phi béo duong cao hon so vot phuong phap tray/transport type systems Lap HCoaTP Trang 23Quy trinh va thiét bj sin xuat kem GVHD: Thay Lé Van Viet Man Hinh 16: Thiét bi lam cing Tray between continuos chain g) Lam cing bang phusng phdp théi gian lu bién déi Varible Retention Time(VRT) > Un diém: > Nhuge dién Lép HCO4TP Cho phép thay d6i thoi khae nhau DE dang hoat dng vai cde wy dong Lam cting déng thoi ede sin phim kich thuoe khée nhau Toc d6 sin xudit cao (trén 10000 GPH) jan lu sin phim vdi hé théng c6 kich thude chu! Chi phi cho ede khay cao Chugng tinh van hanh phate tap Yéu ciu dp sudt cao, khéng thay déi, nang lng cao Hé thing kich thufoe nhé khodng [500GPH Chi phi bio duai a0. Trang 24Quy trinh va thiét bj sin xuat kem GVHD: Thay Lé Van Viet Man Hinh 17: Thiét bj fam cing VRT h) Lam cting bing céch van chuyén ni khay > Uv diém: ~ Hé thing khOng khi dong doi gitip Lam ettng t6t hon ~ Chi phi bad ti thap vai thot gian sif dung lau (trén 30 nim) ~ He thong khong khé higu qui gidim chi phi va nang wong ~ Lam ettng déng thai cdc sin phim kich thude khée nhau = Thiét bj dan gidn nhit so véi thiét bi Lim extng bling phuong phép a¢i khf sin phim loai khay = Chi phi du wy vita phai ~ He théng 10000GPH > Nhuge diém ~ He thong phite tap hon so v6i ~ He thong day dai xodn - Hé théng nhé nhat 750GPH Lép HCO4TP Trang 25Quy trinh va thiét bj sin xuat kem GVHD: Thay Lé Van Viet Man Hinh 18: Thiét bi lam eting bing edch van chuyén nhiéu khay + Qué trinh tao hin a) Thiét bj tao hinh cho kem que: inh cho kem que c6 2 giai doa Giai doan phan chia nguyén liéu: nguyén liéu c6 dang dng dai va duige cat thanh tiing thanh (bar) cé kich thuiée phi hgp. Kich thud ciia cde thanh 06 thé duge diéu chinh bling tc 49 chay cia bung tdi va tin sO hoat dong ciia dao cét. C6 2 dang phan chia: theo chiéu ngang (Horizontal etrusion) va chigu thing ditng ( Vertical etrusion). Hinh 19: Thiét bi ép din ngang Lép HCO4TP Trang 26Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man Hinh 20: thiét bi ép dan ditng. Hinh 21: Thiét bi tao hinh lam ciing két hop Giai doan tao hinh cho céc phdn nhé: cdc phan nhé due may ép khudn dinh hinh thanh cde hinh déng da dang nhw hinh que, hinh tha vat. Lép HCO4TP Trang 27Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man b) Thiét bj tao hinh cho kem conerto: Cometo 1a kem dutge r6t trong banh xp (cone). Quy trinh tao kem conerto khong cdn may phan chia nguyén liu hay méy ép khudn, chi cdn may rét kem, Nguyén the hoat dong cing gn nhur may r6t kem hOp. Hinh 22: Thiét bj r6t kem conerto véi 8 dau rét. ‘Thiét bj trén c6 thé rot cing lic cho 8 banh cone. Mdi dng rét kem cho mét binh cone c6 nhiéu ng nhé bén trong, mi Sng nhd duge nap nhiéu logi kem, ching khde nhau vé mau sie, mdi vi. Khi duge bom dén déu ra cée loai Kem nay sé hod quyén Tai v6i nhau, tao cho san phiim c6 hinh thite rt bat mat vdi nhiéu 6p kem xem ké. Hinh dang kem da dang cdn difgc tao ra bdi_ dau phun, céc diu phun khéc nhau sé go ra hinh dang kem khéc nbau, vi dy nhu hinh xoun 6c, hinh vé sd, hink thép. Lép HCO4TP Trang 28Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man Hinh 23: M6t sé loai dau phun va sin phém cia né. t bj tao ldp 40 chocolate Thiét bi tao lép 40 chocolate bao gdm mét bén chita chocolate dugc pha véi mot s6 cde nguyén ligu phu khéc nhy du phOng, hanh nhan..Kem cay sau khi dutge téch Khudn, dita qua bén chifa dung dich chocolate 6 40°C dé tao ra mt 6p 40 chocolate cho sin phim rdi duge dua vao thiét bi bao géi Lép HCO4TP Trang 29Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man Hinh 24: Cac que kem dugc do chocolate, hoc 1 1p mau cam, Hinh 25: Day chuyén phan chia, ép khudn, g&n que va bao 40 chocolate v. SANPHAM 1) Bao quan: Kem thinh phim duge bio quan trong phdng lanh -30°C, do dae thi riéng vé cfu tric, kem thanh phim can duge bio quan trong diéu kién ding quy dinh dé tanh nhang bién déi va hu héng vé mat chat lugng. Tai co sd sin xudt, nhiét 46 bio quan 1a -30°C. Kem difge van chuyén bang xe Janh 25°C ti nha méy dén noi phn phéi va tiéu thy. Ngudi tiéu ding nén wit kem & nhi€t d6 khong 1dn hon -18°C., Lép HCO4TP Trang 30Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man Néu nhidt d6 ting cao khi béo quan, sé Iam cho lop kem bé mat chdy ra, gay bien dang sin phémm va anh hung dén cu tnic ciia kem. Khi ta tién hanh lanh dng trd lai, mot phin duding lactose trong sifa c6 thé bi két tinh, va ngudi tiéu ding sé cm nhdn duge cdc tinh thé nay khi sit dung kem. Bao quan ding quy dinh, thi gian bao quan ¢6 thé kéo dai tir 6-9 thang. 2) Danh gid chit lugng sin phim: > Chi tiéu cam quan: sin phém gidt nguyén hinh dang, mau mdi vj die tung, > Chi tiéu vi sinh: him lung cdc vi sinh vat gay benh nhu Samonella, Listeria, Staphyloccoccus aureus khéng ldn hon 10 khudn lac/ml sin phim. > Chi tiéu hod I: him lutgng protein, lipid, glucid tng, lactose, 46 dm, ham Iugng khong, vitamin... dao dng trong m6t kho&ng 1dn phy thuge vao dang sin phdm va quy dinh chung cla mOi nude. 3) Cée dang sin phdm kem: * Viet Nam: Thi phdn kem Viét Nam duge phan chia nhu sau: Kido's chiém thi phan cao nit 45,8%, tip dén la Vinamilk 20,8%, Thily Ta 1a 20,8%.. Tai TPHCM, kem Ki Do din dau véi thi phan han 50%, ditng thf 2 12 Vinamilk 40% va thf 3 a Monte Rosa 8%. 6 thi trvng kem trung va cao cffp, Kido’s chiém hin 60% thi phan Hign «i, chuyén phan khue thi trudng kem vdi céc tén tui Idn d% khé 1 rang, véi nhiing wu thé rigng. Vinamilk dang c6 uu thé vé cc logi kem hop, kem mang vé aha, Monte Rosa lai c6 uu thé vé nhém kem cao c&p bin & hé thong cita hang, cn Kido’s v6i 2 nhan higu Merino va Kido's Premium Iai e6 vi thé dain du & mang thi trudng kem cay. j ee San phdm kem Vinamilk + Kem sifa 2500vnd/edy, hufdng chocolate, du phéng va kem vani + Kem ly Dino 100ml 3000 vnd/y, c4c loai: dau, sdu riéng, vani, chocolate, cm, trai cy, khoai mOn, c& phé, déu xanh, dita. + Kem cao clip Vinamilk hop 450m! 15000vnd/hdp, 26000vnd/hOp logi 11 ¢6 cde loai: dau, sdu riéng, vani, chocolate, cém, trai cy, khoai m6n, c& phé, du xanh, dia. Lép HCO4TP Trang 31Quy tinh va thiét bj sin xuait kem GVHD: Thay Lé Van Viet Man San phim kem Kido Hién nay, KIDO’S dang c6 2 nhin chinh la Merino va Kido’s Premium vdi hon 36 sin phdm, trong 46 c6 16 sn phdm mdi so véi kem Wall's g6m cdc chting logi: kem hop, kem hi, kem banh va kem que. Cac sin phém kem rat da dang gdm: Kem Xoti, Kem Mang cfu bén canh nhitng khdu vi quen thudc cla quéc t€ nhu: Kem Chocolate, Kem dau va kem Vani } Nuc ngoai: Sain phim kem cay San phim kem hop Lap HCoaTP Trang 32Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man Sin phdm kem conerto Lép HCO4TP Trang 33Quy trinh va thigt bi san xust kem GVHD: Thay Lé Van Viét Man TAI LIEU THAM KHAO 1, Nhat An, Vigt Hoa, Duong yao nghé-Cng nghe thie phdm, NXB Tré, 2007. Lé Van Viét Min, Céng nghé sdn xudt cdc san phém tit sita, tpl, NXB DH Quée gia TPHCM, 2004 3. Robert T. Marshall, H. Douglas Goff, Richad W-Hartel, Jee Cream, 6" edition, Kluwerr Academic/Pleum Publishers, May 2003. 4. Tetra Pak, Dairy Processing Handbook, Published by Tetra Pak Processing Systems AB, S-221 86 Lund, Sweden. 5. www.whiteysicecream.com.facility.asp 6. www.florenceicecream.itindex.htm 7. www.tepionneer.com.tw.products03.htm N Lép HCO4TP Trang 34