HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY

SCHOOL OF ELECTRICAL ENGINEERING

REPORT

PASTEURIZATION IN ICE CREAM

PROCESS

Instructor: PhD. Dinh Thi Lan Anh

Student name: Tran Đao Nguyen Giap

Student ID: 20212408
Subject: Process Control
Class: 149106

Ha Noi, 06-2024

A. INTRODUCTION
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1. Purpose of the report
Learn about the ice cream process, especially focusing on
Pasteurization.
2. Ice cream overview
Ice cream and frozen desserts are popular throughout the world. Although
ice cream is a popular frozen dessert in all parts of the world, the major
consumer countries of ice cream are New Zealand, the United States, Canada,
Australia, Belgium, Finland, and Sweden. In some areas of the world,
unavailability of appropriate ingredients, lack of refrigerated distribution chain,
economics, or other cultural factors may deter the manufacture (and therefore
consumption) of ice cream. There are several different names for ice cream in
the world. In Norwegian it is iskrem, in Portuguese sorvettes, in Spanish
healdos, in French glace´, in Italian gelato, in Hebrew glidah, in German eis, in
Finnish jatelo, in Greek pagoto, and in Chinese bing qi lin or sou go.

3. Ingredients and their effects

Various ingredients are available in the market for ice cream that have
important effects on ice cream quality. These ingredients can be categorized
into dairy and nondairy components from many sources. Various ingredients
that affect the quality of ice cream include sugar, fat, MSNF, water, emulsifiers
and stabilizers.
a. Sugar
Sugar either in liquid or solid dry form added in ice cream up to 12-20%
but 14-16% is the preferable level
- Function: Optimum palatability, maintain handling properties, acceptability of ice
cream, sweetens the product…
- Defect (higher sugar addition): Bland taste due to lacking sweetness, mask desired
flavor, freezing point depression
b. Water
Water maintains the continuous phase in ice cream either by adding it as
solid or liquid form. Products from dairy origin also contribute water
contents. Water provided from supply source must be purified while it is
expected that water of milk source has been cleaned already during its
passage and excretion from memory glands.
- Function: Act as solvent, provides liquid medium
c. Air
The quality of ice cream is influenced by the amount of air incorporated.
Quality of product can be controlled by uniform addition of air.
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- Function: Increase the volume, meeting legal standards, increase profit…
- Defect: Reduced ice crystals size, reduction in melting point, low
hardness…
d. Stabilizers
Animal source: gelatin from bones and calf skin. Plant or vegetable source:
gums (agar-agar, carboxymethyl cellulose, sodium alginate, acacia, oat,
carrageenan and karaya)
- Function: Smoothens the texture, provide body to the product, freezing
point not affected
- Defect: Restrict whip ability, undesirable melting properties, heavy and
soggy structure
e. Egg
It is highly valuable in foods and helps in other flavors blending for
desirable properties. Ice cream cost is increased by egg yolk addition.
Protein and lecithin complex in egg yolks is highly preferred in mixes
where total solids are lowered and prepared with butter oil or butter
- Function: Delicate characteristic flavor, Texture and body improvement,
viscosity increase
- Defect: Off flavor in egg yolk detectable in final product.
f. Flavour
Flavor can be easily mistaken as taste or feel sensation. It is a very
important ice cream property and results from the mixed flavor of all ice
cream components. Individual taste of any ingredients has effect on “flavor
blend” or “specific flavor” so it makes difficult in detection of specific
ingredient effect on ice cream flavor. Important properties of flavor are
intensity and type.
4. Ice cream process

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a. Ingredients: Prepare standard ingredients for the mix and blending
b. Mix and blend: In the next step the ingredients are blended. Mix blending
can be performed at refrigeration temperatures 408° F (48C) or at warmer
temperatures 1138° F (458° C). Cold batching is the preferred method when
cream, liquid milk, condensed skim are the ingredients.
c. Pasteurization:
The hydrated ingredients are pasteurized and homogenized. Pasteurization
is a heat treatment given to food products to destroy pathogenic (disease
causing) microorganisms. According to the U.S. Public Health Service and
its Pasteurized Milk Ordinance, pasteurization of an ice cream mix requires
that every drop of mix be heated to 1558° F (68.38° C) and held at that
temperature for 30 min. Alternately, every drop of mix should be heated to
1758° F (79.48C) and held at that temperature for 25 s. Pasteurization can
be performed either as a batch operation or as a continuous operation.

In the continuous process, a plate heat exchanger is used. This heat

exchanger has three sections called (a) regeneration, (b) heating, and (c)
cooling sections. In this process the mix is heated to a minimum
temperature of 79.98° C (1758° F) and held for 25 s; raw cold mix enters the
regeneration section where it is heated by the hot pasteurized mix. The
warm raw mix is then homogenized and heated by hot water to 79.98° C
(1758° F). The heated mix flows through a tube called the holding tube for
25 s.
d. Homogenization:
The process of homogenization has been referred to during the
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 pasteurization step. Homogenization of an ice cream mix results in a
smoother eating ice cream. It is a process whereby fat droplets in the mix
are reduced to a uniform size. In unhomogenized ice cream mix, the
average fat droplet size would be around 2– 4 micromilimeter.
Homogenization breaks down the fat globules to an average size of 1 mm
or less. One micrometer is 1/ 25,000th of an inch, a size not visible to the
naked eye. To homogenize the ice cream mix, all the fat must be in the
liquid. The homogenization works around the pressure 150 bar.
e. Cooling and aging
The pasteurized, homogenized mix then is aged in a refrigerated vat. Aging
is a process of quiescent storage of the mix with intermittent agitation for a
period varying from 3 h to 16 h. During the aging process, the fat crystals
that melted during pasteurization recrystallize, the gums or stabilizers also
complete their hydration process, and the proteins complete their adsorption
at the fat/water interface. In the days when gelatin was used as the primary
stabilizer in ice cream, aging times of 12 – 20 h were recommended.
Modern day stabilizers do not use gelatin and require far less time to
complete their hydration. A minimum ageing time of 2 –4 h is
recommended.
f. Add flavor and microcapsule
As a rule of thumb, the higher the fat content of the mix, the more the
flavoring required. Also batch pasteurized mixes, especially if they contain
egg yolk solids, require more flavoring HTST pasteurized mixes. Always
test the effectiveness of the added flavor in the ice cream and not by
judging the quality of flavored mix. Flavors are added in at least three
different ways, namely, (1) directly to the mix prior to freezing (e.g.,
vanilla, chocolate, mint), (2) immediately post freezing (fruit pieces, nuts,
candy, and confectionery pieces); or (3) postfreezing prior to packaging
(ripples and variegates). Modern flavoring systems are complicated and
may use all three of these modes of flavoring in the same ice cream. The
most popular flavors are vanilla, chocolate, fruits, nuts, bakery goods,
confectionery items, and ripples or variegates. Nearly 30% of the ice cream
manufactured is vanilla.
g. Freezing
When freezing ice cream is discussed, it is important to remember that it
concerns the creation of ice from water in the mix. Therefore, the only
constituent of the mix being frozen is water. During the freezing process the
equilibrium between water and ice is altered. Freezing is facilitated by the
removal of heat from a substance. In the old salt and ice machine, used

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 prior to mechanical refrigeration, ice served as the refrigerant and addition
of salt lowered the freezing point of water. The brine extracts heat from the
mix. The mix temperature is lowered and the brine temperature increases.
Brine is not a good refrigerant. With the advent of mechanical refrigeration,
the use of ice and salt for freezing ice cream was relegated to a hobby
status.
h. Packing
A good package must contain the product, protect it, provide convenience
and provide information on the product to the consumer. Food packages
provide protection against physical, chemical and biological damage. It also
provides information useful to the consumer, for example, ingredient label,
nutritional label, net contents, serving suggestion, and methods of preparing
the product. Besides these attributes, a good food package keeps the food at
nearly the same quality as when it was manufactured. During distribution
packages are subjected to physical abuses such as shocks, vibrations,
compression, and in the case of ice cream and frozen desserts, heat shock.
i. Storage
Ice cream is unique in that it is the only product that is consumed in the
frozen state. Therefore, once it is manufactured it must be stored,
transported, distributed, and sold in the frozen state. In the United States,
frozen foods are distributed in a separate chain than ice cream is because
the cold chain for frozen foods is -18° C and is inadequate for ice cream. Ice
cream cold chain maintains -23° C. The distribution chain is called the cold
chain and varies from manufacturer to manufacturer. Regardless of the
variations one thing is certain. The cold chain is imperfect. This
imperfection affects the quality of the product at the point of purchase and
impacts consumer satisfaction. Factors affecting the shelf-life of ice cream
are manufacturing procedures, warehouse equipment, warehouse handling
practices, transportation, storage at retail premises, retail display
equipment, and retail handling practices.

B. PASTEURIZATION PROCESS
1. Overview
a. Introduction
- Pasteurization: it is a process of heating food and liquids to a specific
temperature for a set period and then cooling them immediately.
- Developed by: Louis Pasteur –a French scientist in 19th century
- Application for: food and beverage aspect commonly

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Or Kind of Main purpose Condition of
food processing

1 Food Enzyme inactivation (pectinesterase, 65°C for 30 min;

(pH<4.5) polygalacturonase) 77°C for 1 min; 88°C for 15 s
2 Beer Destruction of spoilage-causing 65°C–68°C for 20 min (in bottle);
(pH < 4.5) microorganisms (wild yeasts, 72°C–75°C for 1–4 min at 900–1000 kPa
Lactobacillus species)
3 Milk Destruction of pathogens: Brucella 63°C for 30 min;
(pH > 4.5) abortus, Mycobacterium tuberculosis, 71.5°C for 15 s64.4°C
4 Liquid egg Destruction of pathogens (Salmonella 64.4°C for 2.5 min;
seftenburg) 60°C for 3.5 min
5 Ice cream Destruction of spoilage 65°C for 30 min; 71°C for 10 min;
microorganisms. 80°C for 25 s

b. Classify
The following figure represents what are types of Pasteurization

- LTLT pasteurization (Batch Pasteurization or Vat Pasteurization) as it is

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 carried out in an agitated kettle in batch wise manner. It involves heating the milk
up to a temperature not less than 62.8°C and holding it at that temperature for a
minimum of 30 minutes. This was the first-time temperature treatment developed
to render the milk free from active microbial pathogens especially Mycobacterium
tuberculosis, the most heat-resistant pathogen of major public health concern in
milk at that time.
- HTST pasteurization is continuous manner in plate heat exchanger with online
detection and recirculation of insufficiently treated milk. It involves heating the
milk up to a temperature not less than 71.5°C and holding it at that temperature for
a minimum of 15 Seconds. The HTST process operationally comprises five stages
viz., regenerative heating, heating, holding, regenerative cooling and chilling in
sequence. The HTST pasteurization is essentially accomplished in a specially
designed PHE installed with additional components like booster pump, steam
battery, holding section, flow diversion valve, back pressure valve, etc. The
biggest advantage of HTST pasteurization is the regenerative heating/cooling of
milk, which reduces the utility requirements by almost 80 to 90% as compared to
batch pasteurization.
- UHT (Ultra High Temperature) Pasteurization refers to the heating of milk to
not less than 80°C and holding at the same temperature for minimum 1.0 second
followed by aseptic packaging. The method of heating can be direct or indirect or
both. The most important advantage of UHT pasteurized milk is that it can be
stored for up to 3 to 6 months without refrigeration. Both LTLT and HTST
pasteurizations destroy most of the vegetative bacterial cells, but it can’t destroy
some thermophiles and spore forming organisms, and this necessitates prompt
cooling and refrigerated storage of LTLT or HTST pasteurized product to arrest
the growth of survivors. However, during UHT pasteurization, almost all
microorganisms including spore formers are killed and therefore such treated
product can be stored at room temperature without cooling unlike first three
methods of pasteurization.
2. Plate heat exchanger overview
a. Introduction
- Heat exchangers are devices used to transfer energy between two fluids at different
temperatures
- The PHE is the most important component in HTST pasteurizer. In its simplest
form, a PHE consists of a front base also known as head terminal, a back base also
known as end terminal, 4 bars known as guiding rail that connect the front and end
terminals forming a frame-like structure. Several thin plates are fitted in the frame
forming a horizontal stack, which may or may not fill the complete frame length.
When the complete length of the frame is not filled with the plate stack, an
additional thick plate known as pressure plate is included as the last supporting
plate and is tighten with a central screw to provide the required contact pressure.

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- The plates are sealed against the two sides and exterior by flexible gaskets made of
nitrile rubber. The structure of an individual plate has four ports for the passage of
liquid and two grooves for engaging the plate on the guiding rail. Two of the four
ports act as inlet and outlet for one liquid (milk or mixture of ice cream) on that
side of the plate and are called open ports. Remaining two ports function as the
bypass passages for other liquid (say water) to another side of the plate. These are
called blind ports. The gasket lining isolates the two ports and prevents the liquid
from entering one side so these are sometime called blind ports or openings. Each
plate is made of polished stainless steel and offers around 1 m2 surface area, the
thickness may vary from 0.5 to 1.25 mm.

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- The total mixture entering in the PHE simultaneously flows through many
alternative plates, downwards and then through same number of plates upward. It
takes a few passes within the plates’ stack before coming out from the terminal.
Likewise, the heating / cooling medium also flows through many plates
simultaneously depending upon its flow rate and takes few passes before reaching
the terminal.
b. Operating principle
- Gasketed plate heat exchangers (GPHE) optimise heat transfer. The
corrugated plates provide easy heat transfer from one gas or liquid to the
other
- Plates for a gasketed plate heat exchanger are with elastomeric gaskets
- The fluids can cross the channels in series (a less common solution) or in
parallel by making counter-current or current configurations.

+ The serial configuration is used when there is a small flow rate for each fluid but
high heat jump
+ The parallel configuration with countercurrent channels is used for high flow rates
with moderate temperature drops and is the most widely used.
+ When there is a great difference between the flow rates (or between the maximum

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permissible pressure drops) of the two fluids, the exchanger can run twice by the fluid
with a lower flow (or higher losses) to balance the values of pressure drops or specific
flow rates in the channels.

c. Problem
- One of the most common problems for plate heat exchangers is an irregular
supply of all channels in parallel.
- In fact, the fluid tends to distribute in greater quantities in the first channels
rather than the last ones to balance the pressure drop.
- As the number of plates increases, even distribution declines, resulting in a
decrease in the overall performance of the exchanger
3. Auxilary devices
- Balance tank: It is a small tank that is placed between the feed tank and
pump supplying mixture to pasteurizer; it acts as a flow stabilizing agent
and ensures constant supply of milk. It also nullifies the effect of milk head
in the silo on the milk flow. By floating the fluid level in the balance tank is
controlled between two limits.
- Holding tube: The mixture heated to pasteurization temperature must be
held at the same temperature for specific duration of time to affirm proper
pasteurization. This is accomplished in a holding section or tube, the latter
being more common. Though ideally, the mixture be heated to minimum
71.7ºC and held for 15 seconds, the actual temperature and the minimum
residence time of milk in the holding section should always exceed. This is
since some drop in temperature of mixture while flowing through the
holding tube is inevitable.
- Boiler: The hot water is generated by the fuel burn and make the steam.
The boiler will provide the exchanging heat flow for PHE. Keep in my that
the pressure and temperature of the boiler and conductor for hot steam are
very high so safety is considered firstly before.
- Coolant: This device decreases the mixture’s temperature and ensures the
desired temperature for mixture before the product goes to storage tank.
4. P&ID of Pasteurization
- Overall, input of the process is mixture from feedtank, and output product is
pasterized mixture. The main machine is plate heat exchanger (PHE) and
auxiliary machines such as boiler, coolant, storage tank…

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- We divide into 4 main parts:
a. Balance tank:
- Firstly, mixed ingredient was fed to balance tank
- Balance tank will provide mixture to regeneration section 1 of PHE and is heated
to 50° C
- After that, this mixture goes to regeneration section 2

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b. First exchanging heat of PHE:
- After going out of the second regeneration section, the mixture is pumped by a
booster pumpto reach the heating section.
- Mixture is heated by hotwater is 80° C .
- Then, mixture goes to holding and keep 25s for pasteurization
- The controller will decide to control FDV that is the decisive component in HTST
pasteurizer that ultimately decides whether the milk approaching it is properly
pasteurized or not 2 valves will determine whether the product is standard or not.

c. Second exchanging heat of PHE:

- On the one hand, pasteurized substance goes back the regeneration section 1 and 2
to exchange the heat with mixture out of balance tank. Finally, it is cooled and
stored in the tank. The cooler is adjusted by the temperature of the output
substance.
- On the other hand, unacceptable mixture will go back the balance tank.

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d. Boiler section:
- Another main object is boiler
- Boiler plays an important role in supplying hot water for PHE
- To ensure the quality we need to measure the temperature of supply flow to control
fuel.
- To ensure safety, we use TC and PC. The water tank plays an important role in
supplying water (cyclic process of exchanging heat) for the boiler and helps to
release the steam of boiler in the higher standard pressure case.

5. Pasteurizer troubling shooting

Or Problem Possible cause Possible solution

(Symptom)
1 Descrease in Fouling of plates either on Carry out complete CIP for
capacity, flow milk side de-scaling. If the problem
rate... persists, dismantle the PHE
and clean the plates
manually.

2 Visible leakage The gasket might have Replace the gaskets

damaged

Operating pressure is Decrease the operating

more than the rated pressure (Sometimes when
pressure booster pump is not
installed in the system,

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 decreasing operating
pressure leads to low
capacity, hence booster
pump must be installed)

3 Low regeneration Less heat transfer area in Increase the number of

efficiency regeneration section plates in regeneration
section

Flow rates less than its Increase the flow rates

rated values

4 Frequent flow Insufficient plates in Increase the number of

diversion heating section plates in the heating section
in accordance with the heat
load

Drop in temperature of Check the working of

incoming hot water steam injection valve

Drop-in flow rate of hot Inspect the hot water

water recirculation pump for
leakage and capacity

C. CONCLUSION

Ice cream is so popular in the world and with cutting edge technology, ice cream
can be created and prevented to ensure the demand of consumer. To ensure the
demand of the market, the first aspect that must be considered is safety quality.
One of them is eliminating harmful factors in ice cream. Pasteurization is applied
for ice cream process with prolonged shelf life of food products, preventing
disease caused by foodborne organisms, quick and safe sanitation of food… Not
only ice cream process but also milk and other aspects of food and beverage apply
Pasteurization. On the other hand, the demerit of Pasteurization can be nutrient
loss, changeable flavor. Therefore, Pasteurization optimization and enhancement
are needed.

D. REFERENCE

 “Milk Pasteurization and Equipment”, A. V. Dhotre, National Dairy Research

Institute

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 P&ID Food Processing Symbols and Their usage
 “Ice cream and Frozen Dessert”, Arun Kilara, Ramesh C. Chandah
 “Effect of different ingredients on texture of ice cream”, Qamar Abbas Syed
 “Modeling and Design of Plate Heat Exchanger”, Fábio A.S. Mota, E.P.
Carvalho, Mauro A.S.S. Ravagnani
 “HTST Reference Guide for training new Operators and Maintenance
Technicians”, Joe White, Youtube.com: HTST Reference Guide for training
new Operators and Maintenance Technicians. (youtube.com)
 “Cedar Crest Ice Cream Virtual Plant Tour”, Youtube.com: HTST Reference
Guide for training new Operators and Maintenance Technicians.
(youtube.com)
 How Ice Cream is Made in Factories | How It's Made: How Ice Cream is Made
in Factories | How It's Made (youtube.com)
 “Pasteurization”, University of GueLph
 “Pasteurization: Types and Advantages”, Diksha Koirala

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