elderflower ice cream development presentation
Post on 18-Nov-2014
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Elderflower Ice Cream Development
Meet the Team…
Finance NPD Technical Production Marketing
Agenda/ Aim to cover
Design Brief
What makes a Dairy Ice Cream?
Food Regulations 1996 Ice cream - must contain at least 5% fat
Dairy Ice Cream - must contain 5% fat from Dairy sources
Anything under 5% fat cannot be declared an Ice Cream
Typical Ice creams contain between 5 – 15% fat
Milk protein – Must contain 2.5% MSNF
Defining your Ice cream…
Low fat Ice cream: 5.5 to 6% fat
Standard: 6-12% fat 50-66% air – light, soft texture
Premium: higher proportion of cream - 12-16% fat
Super premium: lowest over run, 20% air Highest fat content 16-18% fat
Ice Cream Market in Brief Currently worth £1.3 billion
Thriving despite recession and health concerns
Two firths of consumers eat Ice cream all year round
Premium & Luxury Ice creams – strongest performers
3/4 of adults eat tubs of Ice cream – just under half claiming at least once a month
Growth over next 5 years…. Consumers may look at how often they eat it but…. they will still be prepared to pay for premium
What do people look for in an Ice cream? Still a desire for Unhealthy, indulgent treats… Ice cream is regarded as a
“permissible affordable treat” To the majority of consumers “flavour is the most important attribute” Confirmed via survey carried out
Recipe Formulation
Recipes we tested in the kitchen…. Why?
Kitchen Trials
What the trials showed us
Testing the fat content in the lab
Results compared to actual
The Chosen Recipe 16% Fat 12.5% Elderflower:
- 16% Fat – puts us in the super-premium band which is where an elderflower ice cream would belong
- 12.5% elderflower – makes the ice cream refreshing and flavoursome
Ingredient Grams Percentage of mix
Double cream
300g 30%
Full Fat Milk
365g 36.5%
Sugar 120g 12%
Dextrose 40g 4%
Stabiliser 3.5g 0.35%
Skimmed Milk powder
100g 10%
Water 70.5g 7.05%
Elderflower cordial
125g 12.5% of 1kg mix
Scaling upIn order to make 6kg:
Ingredient Grams Percentage of mix
Double cream-
48% fat
1800g 30%
Full Fat Milk – 4% fat
2190g 36.5%
Sugar 720g 12%
Dextrose 240g 4%
Stabiliser 21g 0.35%
Skimmed Milk powder
600g 10%
Water 423g 7.05%
Elderflower cordial
682.75g 12.5% of mix
Yield:Made in two 3kg batches:
Batch 2: 2612kg – loss of 338g=87% yield
Total Made:5462 – loss of 538g= 91% Yield
Adding the Elderflower cordial:12.5% of 5462= 682.75g
Batch 1: 2850kg - loss of 150g= 95% yield
Over run:
Weight of Volume of Mix
Weight of Volume finished ice Cream
Weight of Volume finished ice Cream
-
x 100
= 27.07% over run
Process flow •MIX CALCULATION•FORMULATION•MIXING•PASTEURIZATION•HOMOGENIZATION•COOLING•AGING•FREEZING•PACKAGING•HARDENING•STORAGE
3 Main parts of the process
Process Flow diagram
Potential Micro hazards
Ice cream is a good media for micro growth due to high nutrient value, almost neutral pH and long storage duration.
Some pathogens that can survive in food even at low temperature include Salmonella spp., Listeria monocytogenes, Campylobacter spp. and Yersinia spp.
For ice-cream products, L. monocytogenes is of significant food safety concern worldwide
Trends from past studies
In 1998 – 2000, a total of 16,379 ice-cream samples were taken and examined for TVC and coliform organisms.
61% (10,018 samples) were soft ice-cream products and 39% (6,361 samples) were hard ice-cream products.
Of the period under study, 543 out of 16,379 ice-cream samples (3.3%) failed the stipulated hygienic quality. The corresponding figures for soft and hard ice-cream were 4.9% (492) and 0.8% (51) respectively. It is obvious that majority of the failed samples were soft ice-cream (a case for the hardening of the elderflower ice cream).
TVC/Coliform trends
Hazard table
HACCP Plan summary
HACCP Plan summary table for elderflower ice cream
CCPHazard Critical limit Monitoring Corrective action
Records Verification
Pasteurisation
Bacillus cereus, Listeria monocytogenes and Salmonella
83 degrees for 3
seconds (review)
Temperature probe
RepasteurisationTemperature
logsReview records
Aging
Recontamination/ bacterial growth
5 degreesTemperature
probeRepasteurisation/
discard Temperature logs
Review records
Labelling
AllergensCorrect pack +
segregation
Visual checks DiscardStock +
Packaging checks
Review records
Manufacturing Machinery
Photos of Ice cream machinery, need photoes from cleaning day!!!!!
CCP’s & Technical considerations
CCP’S and how they would be controlled (HACCP plan)
Quality controls (control measures from hazard table + prerequisites i.e GMP & Hygiene)
Shelf life? (2 years)
Cleaning Procedure
Possible bacteria (salmonella, bacillus cereus and listeria). TVC & Coliform indicators from 1998 – 2000 study).
Areas of difficulty. Chemicals and dilutions used and why. Caustic for
fat removal (alkaline) + disinfectant to kill bacteria. Need copy of cleaning instructions.
( We have a talk on this Next week I believe)
Finance…
Break down of the product costing Some info on Target market ( A, B, C1) RRP – per portion Where it will be sold,
Any Questions
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