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Ice cream Industry in Pakistan

By LittleStudent Jul 15, 2012 2141 Words
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|Written by Shahid Hafeez Khan    | |Wednesday, 12 January 2011 17:49 | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |HICO ICE CREAM | |It is situated In Lahore. Its production capacity is 3 million litres per annum. | |  | |ROCOO ICE CREAM | |It is Situated In Islamabad. Its production capacity is 5 million litres per annum. | |  | |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% | |  | |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. | |  | |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. | |  | |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 | |  | |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. | |  | |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. | |  | |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. | |  | |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 | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |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. | |  | |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....

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