Ice cream Industry in Pakistan

|Ice cream Industry in Pakistan |[pi|[pi|[pic|
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|Written by Shahid Hafeez Khan |
|Wednesday, 12 January 2011 17:49 |
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|Ice cream is a cute frozen desert made from a combination of milk products and eggs, sugar dextrose etc. here are small, medium and large |
|manufacturers of ice cream in Pakistan. It has been estimated that total installed capacity for Punjab including recognized manufacturers, |
|hotels, restaurant and unrecognized sector is about 25 million liters annually. The provinces of NWFP and Baluchistan installed capacity has|
|been estimated about 6 million litres per annum (1995). Up to nineties there were only 4 well known brands manufactured in Pakistan namely |
|IGLOO, POLKA, ROCOO and YUMMY. In 1995 a multinational company Lever Brothers (Unilever) Pakistan entered in field and started manufacturing|
|word famous ice cream Wall’s in Pakistan. In Year 2009, Engro Foods limited launched his ice cream with the brand name “Omore”. Omore is |
|dairy ice cream and manufactured at Sahiwal. |
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|Wall's Ice Cream industry |
|In 1995 Unilever started manufacturing of ice cream in Pakistan with brand Name "Wall's". Unilever became the largest ice-cream |
|manufacturers in Pakistan through an amalgamation with Polka in May 1999.It has HACCP and Total Quality Management certification. It is |
|situated in Bhai Pheru .Its production capacity is 30 million litres per annum. |
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|IGLOO ICE CREAM |
|Pakistan Dairy Products, Igloo Ice Cream, is the pioneer ice cream manufacturer in Pakistan & operating since 1974. As a nation wide premium|
|ice cream manufacturer. The Company operates from Karachi; however its distribution network covers a vast area of Sindh and Balochistan. Out|
|of a largely consumed range of scrumptious products, the Supreme Ice Cream range is a market winner with its multitude of exceptional and |
|unmatched flavors such as Strawberry Cheesecake, Cookies N Cream, and lots more mouth watering flavors. Igloo is providing ice cream to its |
|valuable consumers through three different channels, which are tricycles, retail outlets & igloo parlors. These channels ensure efficient |
|delivery & maximum fun & satisfaction to consumers. |
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|YUMMY ICE CREAM |
|It prepares pure dairy ice cream from milk fat. Its production capacity is 10 million litres per annum. t is situated in Koat Lkhpat, |
|Lahore. |
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|HICO ICE CREAM |
|It is situated In Lahore. Its production capacity is 3 million litres per annum. |
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|ROCOO ICE CREAM |
|It is Situated In Islamabad. Its production capacity is 5 million litres per annum. |
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|Definition |
|Ice cream is a frozen desert made from dairy products (milk, cream) combined with flavoring and sweeteners. Modern Commercial Ice Cream |
|Composition 1.10-16% milk fat 2.9-12% MSNF (whey and caseins proteins, carbohydrates ) 3.12-16% sweeteners (sucrose, corn syrup) |
|4.Stabilizers 0.2% 5.Emulsifiers 0.2% 6.55-64% water 7.Total solids 36-45% |
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|LAWS RELATING TO ICE CREAM MANUFACTURE |
|There are many rule and regulations governing the manufacture of ice cream ranging from composition regulations through hygiene to storage |
|temperature. |
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|COMPOSITION |
|Any ice cream sold must comply with the following standards: 1. It must contain: a) not less than 5% milk fat b) not less than 2.5% milk |
|proteins 2. If ice cream is describe as a dairy ice cream then it shall conform to the above composition but the fat shall consist entirely |
|of milk fat. |
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|FOOD HYGIENE REGULATIONS 2006 |
|New food hygiene legislation was introduced in January 2006.This covers all food production in two parts- |
|a) Regulation relates to food of animal origin |
|b) Regulation relates to the hygiene of foodstuffs |
|This regulation gives powers to Local Authority Officers to serve Improvement Notices on unsatisfactory premises, which specify work which |
|must be done. The regulation cover standards required for premises, working areas, equipment and staff also hygiene standards to raw milk, |
|the manufacture of heat treated milk and microbial criteria ICE CREM HEAT TREATMENT LAW These regulations have been amended and apply only |
|to ice cream (contain non milk fat) .However the treatment temperatures remain the same for dairy ice cream as for ice cream |
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|Pasteurization |
|Method 1:A temperature of not less than65.5 c for at least 30 minutes. |
|Method 2:A temperature of not less than 71.1 for at least 10 minutes. |
|Method 3:A temperature of not less than 79.4 c for at least 15 seconds. |
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|Sterilization |
|The mixture should be raised to and kept to a temperature of not less than 148.9 c for at least2 seconds. After heat treatment the mixture |
|must be reduced to 7.2 c or below within 1.5 hours and kept at such temperature until the freezing process begins. The Ice Cream Heat |
|Treatment regulations require the use of indicating and recording thermometers in the equipment in which the ice cream is heat treated, |
|records of such must be kept for at least one month. |
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|INGREDIENT DECLARATIONS |
|Ingredients should be listed in descending order. The name of the ingredient must be the same name as if it were to be sold separately.i.e; |
|fat should be stated as the type of fat used e.g. animal fat or vegetable fat. Quality ingredients must be quantified by percentage. |
|Compound ingredients may be declared in the following way: |
|a) The ingredients of the compound may be declared singly in the ingredient list. |
|b) The name of the compound ingredient may be used with its ingredients listed in descending order after the name of the compound |
|ingredient. |
|c) If the compound ingredient constitutes less than 2 % of the finished product then it may be declared by name only, providing it does not |
|contain any additive or allergens. |
|d) Additive must be labeled with a category and declared by name or serial number. |
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|LAWS FOR ICE CREAM PRODUCTION |
|Manufacturing process of ice cream can be divided into nine steps which are: |
|1. Mixing |
|2. Pasteurization |
|3. Homogenization |
|4. Cooling |
|5. Ageing |
|6. Freezing |
|7. Filling/Packing |
|8. Hardening |
|9. Storage and distribution |
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|MIXING |
|All the basic ingredients are mixed together in a suitable vessel which can be heated. This is usually a steam jacketed, stainless steel |
|vessel fitted with an agitator and connected to a pasteurizer. The mixing vessel may be fitted with a homogenizer which will mix the product|
|at a high shear to break up the fat globule (pre –pasteurization homogenization) or the homogenizer may be fitted in to the exit line |
|(post-pasteurization homogenization)to shear the mix as it is taken to cooler. |
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|Pasteurization |
|As laid down in the Dairy products (Hygiene) Regulation 1995 and the Ice cream (Heat Treatment) Regulation 1959(as amended), all ice cream |
|sold for human consumption must be subjected to heat treatment. |
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|Homogenization |
|Not all manufacturers have a homogenizer fitted in to the production process line as it is not an essential part of the process. If some one|
|is fitted the resultant ice cream has a finer texture and can be whipped more easily at the freezing stage. The homogenizer may be fitted to|
|the mixing vessel so the mix is homogenized before heat treatment or may be fitted so that the mix passes through it after heat treatment at|
|temperature prior to being cooled. |
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|Cooling |
|After heat treatment the ice cream mix must be cooled to a temperature below 7.2 c within 90 minutes. This is done by passing the mix |
|through a cooling device either by a plate heat exchanger in larger scale manufacture or by running it over plates cooled by chilled water |
|or a refrigerant. It is important that this cooling is as rapid as possible to ensure the mix passes through the temperature zone (5-63c) in|
|which most bacteria are able to grow. Again the temperature at exit should be monitored and recorded. |
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|AGEING |
|The mix once cooled is put into an ageing vat. This vessel has a means of cooling the mix and keeping it below a temperature of 7.2 c |
|(preferably 0-4 c) and is fitted with a stirrer to enable the mix to be gently agitated and a recording device to monitor temperature. The |
|mix is then left to age for a length of time not exceeding 72 hours. This enables the milk proteins and stabilizer to become fully hydrated |
|and the fats to crystalline and hardened and has the effect of increasing the viscosity of the mix making it easier to whip and giving a |
|finer, smoother-textured ice cream. |
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|FREEZING |
|If the ice cream is to be sold as a soft serve ice cream, it will be frozen in horizontal batch freezer specifically designed to dispense |
|the ice cream from the front of the machine. There are two type vertical and horizontal batch freezers. Vertical freezer has the freezing |
|cylinder or barrel mounted vertically and the temperature is lowered either by immersion in calcium chloride brine solution or by coils |
|around the cylinder through which are circulated refrigerant gases. Horizontal freezers have the cylinder mounted horizontally and the |
|beating apparatus designed so that the ice cream is propelled towards the front of the cylinder where discharge port is located. Due to the |
|horizontal alignment of the cylinder if is possible to incorporate more air with this freezer so recipe with higher total solids (32-36%) |
|can be frozen. |
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|FILLING/PACKING |
|Whichever freezer is used the ice cream on exit will be in the region of -2c to -7c and still be quite soft. It is at this stage that |
|inclusions such as fruit, nuts, and flavor pieces may be added by way of a fruit feeder or the ice cream rippled. It is then packed into its|
|final packaging and taken to the blast freezer to be hardened. |
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|HARDENING |
|Part from the soft serve ice cream designed to be eaten straight away from freezer the ice cream is too soft to keep for any length of time |
|so it is put in to freezer to further harden. Rapid freezing by way of blast freezer will ensure that the ice crystals remain so small |
|keeping a smooth texture to the ice cream. Temperatures are around -20c to -25c. |
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|STORAGE AND DISTRIBUTION |
|The finished product if kept at around -20c to-25c will have a shelf life of 12-18 months. A distribution temperature of -25c to-30c is |
|recommended as fluctuations around this area cause less danger. |
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|FOOD SAFETY |
|The Centre for Disease Control and Prevention estimate food borne disease causes 76 million illnessses and 5000 deaths in the United State |
|annually. The majority of the illnesses occur in foodservice establishment and in the home. However food processing plants are not exempt |
|from fooodborne out brakes and product recalls. Examples of product recalls include ice cream contaminated with Salmonella enteritidis. |
|Foodborne outbreak and product recalls destroy the reputation business. Potentially hazardous dairy products may be contaminated with |
|foodborne pathogens. Also food ingredients such as dry milk powder are considered to be potentially hazardous because reconstituted (water |
|added) milk powder will support microbial growth. Good manufacturing practices and Hazard Analysis Critical Control Point systems will |
|ensure a safe high quality food product. Time and temperature control is essential for processing food. Most bacteria that cause illness |
|thrive in the temperature danger zone between 5c and 60c.keep hot food hot and cold foods cold is a good rule for food safety. |
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|GOOD Manufacturing Practices |
|To produce and sell food for human consumption food business must confirm to Good Manufacturing Practices. The GMPs include following areas:|
|Equipment and procedures |
|Personal |
|Process and grounds |
|Process and control |
|Sanitary facilities and controls |
|Sanitary operations |
|Hazard Analysis Critical Control Points |
|Hazard Analysis Critical Control Points is a systematic approach to food safety.HACCP involves identifying and assessing hazards associated |
|with food production. Once the food safety hazards are identified, controls are implemented to reduce or eliminate the identified hazards. |
|Hazard may be biological, chemical, or physical. A biological hazard exists when potentially hazardous foods are inadequately processed or |
|prepared. A chemical hazard would include storage of cleaning agents or pesticides in a food processing area, increasing the risk of |
|accidental contamination of food. Physical hazards may include extraneous material, such as grease from pump, contaminating food in a |
|processing plant to metal shavings contaminating menu items in a food service establishment. |
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|By : Shahid Hafeez Khan: MSc (Hons) Food Tech. working as Quality Control Manager-Field, Engro Foods Limited |

I am doing a job in Rawalpindi and in the evening doing MBA in Human Resource Management from Preston University Islamabad Campus. I am in my 8th semester. The University gave me a project report to submit by end of this month July 2012. I require a Project Report on the Topic''Current Market Structure for Ice Cream in Pakistan''. I know you are expert and sitting in the market of business, thus you can arrange it easily from someone for me. Please help me. I am waiting for your reply. Thanks for your cooperation. Bye. waiting....