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