Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

MUC LUC

I. TONG QUAT VE KEM------------------------------------------------------------------2 Gii thieu chung ---------------------------------------------------------------- 2 Nguyen lieu---------------------------------------------------------------------- 2 II. QUY TRNH SAN XUAT----------------------------------------------------------------5 Giai thch quy trnh cong nghe ------------------------------------------------ 6 1. Chuan b nguyen lieu----------------------------------------------------------- 6 2. Phoi tron ------------------------------------------------------------------------- 6 3. ong hoa ------------------------------------------------------------------------- 7 4. Thanh trung ---------------------------------------------------------------------- 9 5. U chn----------------------------------------------------------------------------- 9 6. Lanh ong s bo -------------------------------------------------------------- 10 III. GII THIEU THIET B -----------------------------------------------------------------8 1 Thiet b lanh ong -------------------------------------------------------------- 8 2 Thiet b tao hnh, lam cng -------------------------------------------------- 16 3 Thiet b tao vo ao chocolate ------------------------------------------------- 28 IV. SAN PHAM ------------------------------------------------------------------------------- 29 V. TAI LIEU THAM KHAO ------------------------------------------------------------- 33

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I. TONG QUAN VE KEM GII THIEU CHUNG Ngay nay, kem la mot san pham c tieu thu rong rai moi quoc gia, va thu hut ngi tieu dung moi la tuoi khac nhau, nhng t ngi biet rang kem co mot lch s kha lau i. Kem an xuat hien the ky th 4 trc cong nguyen, cac quoc gia nh La Ma, Trung Hoa phuc vu cho vua chua bang cach lay a lanh tren cac nh nui cao ve tron vi cac loai trai cay hoac sa tao thanh mon kem. Theo truyen thuyet th Marco Polo a mang b quyet che bien kem t Trung Quoc ve My, sau nay ngi My a bien viec san xuat kem thanh mot nen cong nghe che bien phat trien manh me. Nam 1946, ba Nancy Johnson ngi New York a phat minh ra mot loai tu lanh chuyen dung e cha kem, may lam kem ngay nay c mang ten Johnson Patent Ice-Cream Freezer. Nam 1962, cong nghe lam kem thng mai lan au tien c cap bang sang che. Cung vi thi gian, nganh san xuat kem phat trien manh me cho ra i nhieu dong san pham: kem hop, kem ly, kem chocolate, kem trai cay, kem vani, kem corneto kem tr thanh mon an trang mieng a thch cua ca tre em lan ngi ln. Theo thong ke cua Hiep hoi kem an the gii, loai kem pho bien nhat la kem vani29%, ke en la kem chocolate-8.9%, kem hat de va kem dau-5.3%, kem tong hp4.2%, kem boc chocolate-3.9%, kem vanola kieu Phap-3.8%. Theo so lieu cua Hiep hoi cac nha san xuat sa va cac san pham t sa, My la quoc gia san xuat kem an ln nhat the gii vi 61.3 trieu hectolit/nam, ke en la Trung Quoc 23.6 trieu hectolit/nam. Tuy nhien, New Zealand lai la nc tieu thu kem manh me nhat the gii vi 26.3 trieu hectolit/nam, ke en la My 22.5 trieu hectolit/nam. Trung bnh, mot ngi New Zealand s dung 26.3 lit kem/nam, trong khi o mc tieu thu kem cua ngi Trung Quoc la 1.8lit/nam. Mc tieu thu kem trung bnh cua ngi Viet Nam la 0.3 lit/nam. NGUYEN LIEU TRONG SAN XUAT KEM 1) Sa va cac san pham t sa: Tao nen gia tr dinh dng va hng v cho kem. Sa dung cho san xuat kem co the la sa ti, sa bot nguyen cream, sa bot gay, chat beo t sa nh cream, b, hay chat beo khan Yeu cau quan trong oi vi sa lam kem la phai co ham lng chat beo cao, lng chat beo trong sa la yeu to giup tao nen cau truc ac trng cua san pham. 2) ng: ng giup tao v ngot, hieu chnh ham lng chat kho, tang gia tr dinh dng va gop phan tao cau truc san pham. Ngoai ng lactose co san trong sa, thng s dung ng saccharose, ng nghch ao va syrup giau fructose. My va Chau Au con s dung chat ngot ngheo gia tr dinh dng nh sorbitol, aspartam, polydextrose e san xuat kem phuc vu cho ngi b tieu ng hay beo ph.
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3) Chat beo: Chat beo la thanh phan chu yeu tham gia vao cau truc cua kem, co the s dung dau thc vat nh dau nanh, dau cai, dau da hay dau hng dng ket hp vi chat beo cua sa e san xuat kem. Ham lng dau thc vat co the chiem 6-10% khoi lng kem thanh pham. 4) Chat nhu hoa: Chat nhu hoa co vai tro tang kha nang lien ket gia cac hat cau beo, ieu nay quyet nh ln en kha nang gi nc cua kem. Trong san xuat kem co the s dung chat nhu hoa thong dung nh long o trng nhng gia thanh thng kha cao, ngoai ra co cac loai chat nhu hoa khac re tien hn nh mono hay diglyceride, cac ester cua sorbitol hay cua cac phan t ng 5) Chat on nh: Cac chat on nh tao ra mang li khong gian e han che s chuyen ong t do cua cac phan t nc, nh o trong qua trnh lanh ong hon hp nguyen lieu e san xuat kem, cac tinh the a xuat hien se co kch thc nho, kem tr nen ong nhat. Chat on nh dung cho san xuat kem thng co ban chat protein nh gelatin, casein, albumin, globuline hay carbohydrate nh agar-agar, gum arabic, CMC (carboxymethylcellulose) 6) Chat tao hng: Hng lieu cung vi s tao hnh kem tao ra s a dang cho san pham kem. Cac loai hng lieu thng s dung nh vanilla, mui cam, mui sau rieng, dau, chocolate, mui ca phe Chung c trch ly t thc vat hoac c san xuat bang phng phap tong hp hoa hoc. Ngoai ra, trong san xuat kem, ngi ta cung co the bo sung tht qua cat nho, cac loai hat (ho ao, hanh nhan, ph, hach, ho tran, au phong, ieu), bot cacao, dch chocolate Nhng nguyen lieu tren ngoai muc ch tao hng con giup tang gia tr dinh dng cho kem thanh pham. 7) Chat mau: Mau sac tao s loi cuon hap dan cho kem t cai nhn au tien. Cac nhom san pham can tao mau la cac san pham kem co hng v trai cay. Kem co hng v trai cay nao th can co mau cua loai trai cay ay, v du nh kem nho can co mau nau o, kem sau rieng co mau vang Nhom chat mau t nhien co o ben mau kem hn so vi chat mau tong hp trong ieu kien san xuat cong nghiep. Viec s dung chat mau tuan theo quy nh s dung phu gia moi quoc gia. 8) Nguyen lieu khac: Nc va khong kh: Nc co tac dung tao tinh the a, tao o cng can thiet va tao cam giac mat lanh khi s dung san pham. Khong kh giup cho san pham co o mem, xop.

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Acid: viec bo sung acid hu c nh acid citric, acid tartricngoai viec tao o chua thch hp cho kem, con co tac dung c che s phat trien cua mot so vi sinh vat co trong san pham. Phu gia chong vi sinh vat: thng s dung natri benzoat, tuy nhien nhieu nc tren the gii khong cho phep s dung phu gia nay. Tinh bot: trong cong thc kem cua nhieu nc tren the gii thng khong s dung, nhng cac nha san xuat kem cua Viet Nam thng s dung tinh bot bnh thng hay tinh bot bien tnh nham muc ch gia tang o ket dnh cua khoi kem. II. QUY TRNH CONG NGHE

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Nguyen lieu chnh: Sa, cream, bot sa gay, syrup ng

Nguyen lieu phu: chat tao nhu, chat on nh mau, mui

Chuan b

Phoi tron ong hoa Thanh trung U chn Lanh ong s bo

Chuan b

Hop /ly

Rot hop/ly Lanh ong ket thuc

o khuon Lanh ong trung gian Que at que vao khuon kem Lanh ong ket thuc Thao khuon Tao mang bao chocolate Bao b Thung Bao goi Xep vao thung Kem que

Thung

Xep vao thung

Kem hop/ly

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GIAI THCH QUY TRNH CONG NGHE: 1) Chuan b nguyen lieu Nguyen lieu c nh lng theo ung cong thc phoi tron cho moi loai kem san xuat. Nguyen lieu kho c em can, nguyen lieu dang long co the can hay o the tch e xac nh ham lng can s dung. oi vi chat beo phai c gia nhiet len 35-50oC e de phoi tron. 2) Phoi tron Nguyen lieu c a vao thiet b phoi tron theo mot trat t nhat nh, s dung qua trnh c hoc e lam nguyen lieu c ong nhat. S dung thiet b phoi tron hnh tru ng vi bo phan ieu nhiet va canh khuay hoat ong toc o cao, nhiet o phoi tron thng la 50-65oC. Co the ket hp loc va bai kh sau phoi tron nham muc ch tang hieu qua truyen nhiet, ho tr qua trnh ong hoa va thanh trung.

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Hnh 1: He thong bon phoi tron cua Tetra Pak 3) ong hoa Trong san xuat kem, hon hp nguyen lieu thng co cha ham lng chat beo cao, do vay phai s dung qua trnh ong hoa nham lam giam kch thc cac hat beo va phan bo eu chung trong hon hp. Ta s dung thiet b ong hoa hai cap, ap suat dao ong trong khoang 140-250bar. Hon hp c gia nhiet len 65-75oC trc khi vao thiet b ong hoa. Giai oan ong hoa au tien thng s dung 2/3 en 3/4 ap lc tong, kch thc hat phan tan sau ong hoa la 10-12 microns. Tac ong cua ap suat en qua trnh:

Hnh 2: Tac nhan ap suat anh hng en cac hat cau beo trong he nhu tng. A) Mau tham khao, 141-35 kg/cm2; B) Khong ong hoa; C) 281-35 kg/cm 2 ; D) 35 kg/cm 2. 800.
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Kch thc

Tnh chat, cam quan

Chat tao nhu

Yeu cau chat tao nhu khong cao S tan chay Khong tac ong en s tan Lam cham s tan chay kem chay nhng lam mat mat 1 lng nho chat beo. Chi ph nang lng Tieu ton nang lng nhieu. Tiet kiem 1 phan nang lng Ap suat Ap suat cao t 4000-30000 Ap suat thap t 500-2500 psi, tuy lng beo trong psi khoi tron. Khoi kem sau pha tron ac biet oi vi khoi t beo oi vi khoi co ham lng (pha phan tan t) muon tao chat kho cao va nhieu beo, s ong nhat hn na th bat san pham khong oi hoi o buoc phai s dung phng ong nhat toi a th co the phap nay. ap dung phng phap nay cho ton nang lng. ng dung oi vi san pham oi tng san pham ng dung cho dong san pham cao cap, oi hoi chat co s ket hp pha phan tan mc o va phai. lng cam quan sau sac. Chi ph thiet b Cao, oi hoi o ket cau oi hoi t hn vng chac cua thiet b. Chi ph van hanh Cao Thap

ong hoa ap suat cao Kch thc cua cac hat cau beo phan tan nho en mc toi a (0.1-0.3 m) Giup on nh bot kh va tao s trn bong be mat kem. S phan bo pha phan tan tr nen ong eu, cau truc on nh. Giam o nht Tranh hien tng ket tinh a. Can chat tao nhu nhieu hn

ong hoa ap suat thap Kch thc hat cau beo ln hn, tuy theo yeu cau san pham. Be mat kem khong on nh. S phan bo khong ong eu.

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4) Thanh trung Hon hp nguyen lieu can c thanh trung e tieu diet hoac c che he vi sinh vat va enzyme, che o thanh trung thng c chon la 83-85oC trong 15 giay, hoac thanh trung 63oC trong 30 phut. Trong thc te san xuat 2 qua trnh thanh trung va ong hoa thng c tien hanh xen ke. au tien hon hp nguyen lieu c dan vao thiet b trao oi nhiet e hieu chnh nhiet o, sau o c dan vao thiet b ong hoa, roi lai c quay tr lai thiet b trao oi nhiet e thanh trung va lam nguoi.

Hnh 2: Thiet b thanh trung HTST 5) U chn Nguyen lieu sau khi thanh trung va ong hoa c lam lanh ve 2-4oC, sau o em i u chn. Muc ch cua qua trnh nay la lam cho hon hp nguyen lieu at c mot so tnh chat hoa ly can thiet, chuan b cho qua trnh lanh ong tiep theo: cac chat protein se c hydrate hoa hoan toan, mot phan chat beo ket tinh, mot so phan t protein se hap phu len be mat tiep xuc pha gia cac hat cau beo va pha lien tuc. Ket qua lam cho kem thu c sau qua trnh lanh ong se co cau truc mn va ong nhat. Qua trnh u chn c thc hien trong thiet b vo ao trong 4-24 gi, nhiet o 2o 4 C. Lp vo ao ben ngoai co tac dung lam lanh va cach nhiet, han che s ton that nang lng, ben trong thiet b co canh khuay hoat ong lien tuc, khuay cham va eu an.
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Hnh 3: Thiet b u chn 6) Lanh ong s bo Qua trnh nay co hai muc ch quan trong: Thoi mot lng khong kh vao hon hp nguyen lieu e lam tang the tch cua chung. Lanh ong mot phan nc trong hon hp e tao cac tinh the a vi kch thc that nho va ong nhat, ong thi phan bo eu cac tinh the a nay trong hon hp. Tuy thuoc vao loai san pham ma lng khong kh thoi vao hon hp la khac nhau. Thong thng, the tch hon hp sau khi nap khong kh tang t 80-100%. Cac bot kh that mn xuat hien trong kem se tao nen cau truc ac trng cho san pham. Khong kh c s dung trong san xuat kem can c x ly bi he thong loc nham loai cac tap chat nh bui va vi sinh vat nham am bao chat lng cua kem thanh pham. Trong giai oan lanh ong s bo co khoang 30-70% lng nc ket tinh, tuy theo phng phap tao hnh kem ma ngi ta se hieu chnh ty le nc ket tinh giai oan nay cho phu hp. Sau qua trnh lanh ong s bo ta thu c kem ban thanh pham vi cau truc rat mem va xop. Tiep theo tuy theo tng qua trnh tao hnh se thc hien theo cac phng phap khac nhau, se c trnh bay chi tiet phan gii thieu thiet b san xuat. III. GII THIEU THIET B SAN XUAT 1) Thiet b lam lanh Lanh ong la ha nhiet o cua san pham xuong di nhiet o ket tinh cua nc trong san pham o. Co 3 phng phap lam lanh ong chnh la: + Lanh ong bang thiet b hoat ong theo chu trnh lanh. + Lanh ong bang cach tiep xuc vi chat tai lanh bang kim loai. + Lanh ong bang cach nhung trong kh nen long.

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Trong cong nghe lam kem th thiet b hoat ong theo chu trnh lanh c s dung pho bien, Thiet b nay hoat ong theo chu trnh lanh gom 4 giai oan: +Giai oan 1: Tac nhan lanh c may nen kh nen di ap suat cao e hoa long. +Giai oan 2: Tac nhan lanh long c cho qua thiet b ngng tu e toa an nhiet (ngng tu) ra moi trng ben ngoai (dan nong). +Giai oan 3: Tac nhan lanh long sau khi i qua thiet b ngng tu c cho vao van tiet lu. Khi i qua van tiet lu, tac nhan lanh long b giam ap suat ot ngot, boc hi. +Giai oan 4: Tac nhan lanh boc hi trong thiet b boc hi. V qua trnh nay thu nhiet nen moi trng xung quanh thiet b boc hi b mat nhiet lng, giam nhiet o xuong. Trong phng phap lanh ong bang thiet b hoat ong theo chu trnh lanh ta co 2 phng phap lanh ong kem thng c s dung la: Lanh ong gian oan: lanh ong tng lng hon hp phoi tron tai mot thi iem, lien tuc thao hon hp kem ra. Thiet b lanh ong gian oan th t phc tap hn so vi thiet b lanh ong lien tuc. Trong moi me thc hien qua trnh lanh ong th san pham c o lng, bo sung mau, mui va lanh ong rieng biet tng phan. Kieu lanh ong nay c chon s dung khi san xuat kem quy mo nho hoac th nghiem san xuat san pham trong phong th nghiem. Lanh ong gian oan th t ton kem chi ph lap at hn lanh ong lien tuc va no cho phep tao ra nhng san pham kem co mui ac biet vi the tch nho, qua trnh ong goi c thc hien thu cong. Lanh ong gian oan thong thng c thc hien trong thiet b hnh tru nam ngang co sc cha nguyen lieu t 15-40 lit. Nhiet o cua moi chat lam lanh thng c ha xuong -23C-29C e hnh thanh nhng tinh the a nho, tuy nhien cac tinh the a tao ra trong san pham khi thc hien qua trnh lanh ong gian oan van ln hn so vi phng phap lanh ong lien tuc. Lanh ong gian oan thng c s dung cho me kem co the tch 2-40L, moi me mat 15-20 phut e thc hien qua trnh lanh ong.

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Hnh 4: Thit b lanh ong s bo hoat ong gian oan Lanh ong lien tuc la phng phap c phat trien gan ay, phng phap nay co the at c nang suat len en 150-3000L/h. Phng phap nay c ap dung cho san xuat quy mo ln. Phng thc van hanh: hon hp kem c bm lien tuc vao thiet b lanh ong hnh tru, kh se c cung cap bi may nen. Nhiet o trung bnh cua kem khi lanh ong lien tuc la khoang -5C khi nhiet o tac nhan lanh cua dan bay hi ong xoan -30C, tai nhiet o nay th 40% tong lng nc trong kem b ong bang Thiet b lanh ong lien tuc Hoyer cua tap oan Tetra Pak co dung tch hoat ong la 10l/h-4000l/h. Thiet b lnh ng Hoyer KF 1) Thiet b Hoyer KF c cung cap cho nhng nha may san xuat kem tren quy mo ln, c t ong hoa va san pham at tieu chuan chat lng cao. Thiet b Hoyer KF th hoan toan khac cac thiet b lanh ong khac cac yeu to c ban nh: toan bo thiet b c lam bang thep khong r, co gng quan sat e biet c qua trnh lanh ong ket thuc, thep khong r chu c s va cham va co the dng qua trnh lanh ong mot cach de dang. Moi loai model cua thiet b nay eu co he thong ieu khien, van hanh khac nhau. N-model c ieu khien bang cach nhan cac nut ieu khien chnh nh: moto, lanh ong va bm. Overrun control at c bang cach thng xuyen duy tr ap lc khong kh . XC-model la mot thiet b lanh ong hoat ong c ieu khien hoan toan t ong. u iem cua thiet b nay la: de dang van hanh thiet b, co man hnh vi tnh the hin o th va cac thong tin nh: nhiet o va lu lng phoi tron, nhiet o cua kem, lu lng khong kh, o nht cua kem Model Hoyer KF 80 Hoyer KF 500N Hoyer KF 500XC Hoyer KF 1000N Hoyer KF 1000N-2 Hoyer KF 1000XC Hoyer KF 2000N Hoyer KF 2000XC Hoyer KF 3000XC Hoyer KF 4000XC
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Nng sut (l/h) 10-100 75-500 50-500 150-1000 100-1000 100-1000 350-2300 230-2300 300-3000 400-4000
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2) Thiet b lanh ong Hoyer Figus (gom cac model t 200-600): la thiet b hnh tru c lam lanh theo chieu doc, be mat c ma Cr. Mot bm piston dung e o lng hon hp kem va lng kh vao.

Model Hoyer Figus 200 Hoyer Figus 300 Hoyer Figus 400 Hoyer Figus 600 Hoyer Figus 1200

Nng sut (l/h) 90-220 180-300 170-450 150-600 106-317

Trong san xuat kem ngi ta s dung thiet b lanh ong co ong chay (continous ice cream barral freezer). ay la thiet b lanh ong lam viec lien tuc. Cau tao cua thiet b lanh dung trong san xuat kem nh sau:

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Hnh 5 : Mo hnh cau tao cua thiet b lanh ong s bo Nguyen ly hoat ong cua no giong nh may lanh cong nghiep, tuy nhien cau tao cua no khac vi may lanh cong nghiep. iem khac nhau chnh la c cau lam lanh dang ong barrel freezer co cau truc nh sau

Hnh 6: Cau truc barrel freezer cua may lanh ong s bo ay la mot ong dai co nhieu lp. Trong o co lp cach nhiet, lp tai lanh va phan loi cha hon hp nguyen lieu. Trong phan loi nay co canh khuay. au ra cau ong con co them dao cao va cac khe e ay kem ra ngoai. Thiet b nay lam viec che o lien tuc, thi gian e nguyen lieu chay suot ng ong khoang 15-20 phut. Ong co the ong bang khoang 50-70% nc trong nguyen lieu. Hon hp nguyen lieu khi i vao ong va c lanh ong, va c khuay tron k. ieu nay lam cho cac tinh the a rat nho, tao nen o xop cho san pham. Mat khac, do nc trong san pham cha ong bang het nen nguyen lieu ra khoi thiet b van con o set, o mem nhat nh. V vay, thiet b nay con c goi la thiet b lanh ong s bo. Nguyen lieu ra khoi thiet b dang paste,

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sau o nguyen lieu c phoi tron vi mt, trai cay mieng, au phong, hanh nhan va chuyen qua giai oan tao hnh.

Hnh 7: Thit b lnh ng s b

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Hnh 8: u ra ca berrel freezer

Hnh 9: sn phm dng paste sau qu trnh lnh ng s b 2) Thiet b lam cng, tao hnh
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Qua trnh lam cng: Qua trnh lam cng tao o vng chac cho cau truc kem va tao hnh cho san pham. San pham kem sau khi ra khoi thiet b lanh ong s bo co the c chia thanh hai nhom: Nhom khong can lam cng tao hnh: bao gom kem hop, kem ti, cung cap cho cac may ban kem lu ong, kem cung cap cho nha hang, nha san xuat thc an e bo sung vao san pham cua mnh. Vi nhom san pham nay, kem sau khi lam lanh ong s bo c rot trc tiep vao hop, bnh cha e trong kho lanh hay van chuyen trc tiep en ni s dung. Nhom can lam cng tao hnh: nhom nay gom kem cay, cac loai kem co hnh dang, kem sau khi c lam lanh ong s bo se c a vao may lam cng tao hnh. Lam cng thc chat la qua trnh ket tinh hoan toan nc trong san pham, qua trnh nay phai c thc hien nhanh, tao ra cac tinh the a rat nho; ieu nay lam cho kem co cau truc cng chac nhng van co o xop khi s dung. Nguyen lieu sau khi c lam lanh ong s bo c a qua he thong lam cng. He thong nay co ban chat nh mot may lanh, nhiet o gian lanh co the at en -80oC, thi gian lu cua nguyen lieu khong qua 2 phut. Moi chat lanh thng s dung la NH3, Nit long hay a kho CO2.

Hnh : Nguyen ly hoat ong cua c cau lam cng. Nguyen lieu c van chuyen trong cac ng ong, moi chat lanh hay khong kh lanh c phun trc tiep vao khoang khong gian gia cac ong. C cau tao hnh thng c tch hp cung vi c cau lam cng thanh mot he thiet b. Co the tao hnh roi lam cng hoac ngc lai.
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GVHD: Thay Le Van Viet Man

Tao hnh trc, lam cng sau, c cau lam cng dang bang tai: nguyen lieu sau khi tao hnh c at len bang tai, khong kh lanh c thoi trc tiep vao he thong, bang tai chuyen ong a nguyen lieu vao buong lanh e lam cng.

Hnh 10: C cau lam cng dang bang tai Tao hnh sau khi lam cng, s dung he thong lam cng dang ong: nguyen lieu c nap vao cac ong, he thong ong nay c at trong buong lanh, khong gian gia cac ong cung c thoi khong kh lanh vi toc o cao. Tuy nhien nguyen lieu khong tiep xuc trc tiep vi chat tai lanh, ngay nay ngi ta s dung moi chat lanh bay hi trc tiep phan khong gian nay, ieu nay giup giam ton that nhiet va chi ph cho quat gio. Tuy nhien cau tao cua buong lam cng dang nay phc tap hn, oi hoi o kn nghiem ngat e tranh lam thoat moi chat lanh.

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Hnh 11:Thiet b dang ong tunnel Li ch cua phng phap lam cng nhanh: - Chat lng tot hn. - Cau truc kem mn hn. - t b anh hng khi bao goi bang ba cng trong qua trnh cat gi va phan phoi. - Tnh on nh kem tot hn trong cac bao b co kch thc va hnh dang . - Chi ph nhan cong va van chuyen thap hn. Cac phng phap lam cng thong dung: Lam ong lanh Nhung chm Khuon kim loai (a, tam) oi lu khong kh Ket hp khuon kim loai va oi lu khong kh a) Lam cng bang phng phap lanh ong: u iem: - Thi gian lu gi kem ngan - Cau truc be mat kem rat mn - Chat lng toan bo san pham tot hn Nhc iem: - Ton chi ph
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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

- Quy trnh yeu cau khu vc sx rat ton kem - Cac bo phan may moc phai am bao ve sinh

Hnh : Lam cng bang phng phap lanh ong (cryogenic hardening) b) Lam cng bang phng phap nhung chm: u iem: - Phng phap tot nhat e lam san pham dang que - Thi gian lu gi san pham ngan nhat - Toc o san xuat nhanh vi mc o t ong hoa cao - Chat lng san pham cao - Qua trnh truyen nhiet hieu qua cao Nhc iem - Qui trnh he thong n le - Yeu cau khu vc san xuat ton kem - Yeu cau thiet b phai am bao ve sinh - Mot vai bo phan thiet b thai nc tha nhieu - S hao hut san pham trong qua trnh san xuat tng oi cao - Chi ph cho tng bo phan san xuat cao

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Hnh 12: thiet b lam cng bang phng phap nhung chm c) Lam cng trong khuon: u iem - San xuat san pham co dang hnh vuong hay hnh ch nhat - Thi gian lu gi san pham ngan nhat - Qua trnh truyen nhiet hieu qua - Yeu cau khoang khong gian nho vi chi ph san xuat t ton kem - S ton that trong qua trnh lam cng rat t Nhc iem: - Khoang 5% san pham co hnh dang khong ong eu - Ton chi ph cho nhng san pham khong c lam cng - San pham b anh hng khi khong c rot ay - Yeu cau nhiet o lam ong thap

Hnh 13: thiet b lam cng dang tam (plate)

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

d) Lam cng trong pallet vi luong khong kh lanh: u iem: - n gian ve may moc so voi cac phng phap oi lu khong kh khac - au t chi ph thap - Kch thc bao goi a dang - Chi ph bao dng may thap Nhc iem: - Hieu qua lam cng thap - Yeu cau theo doi nghiem ngat e am bao chat lng san pham - Chi ph nhan cong cao - S hao hut san pham cao - Hnh dang ong goi khong ep

Hnh 14 : Thiet b lam cng trong pallet vi luong khong kh lanh. e) Lam cng bang day chuyen xoan oc: u iem: - May moc n gian hn so vi phng phap oi lu khong kh t ong - khac - Hieu qua lam cng cao v cac thong so cai trc - au t von t thap ti va phai - Lam cng ong thi cac san pham co kch c khac nhau - S hao hut san pham thap - Kch thc co san trong he thong t 250GPH Nhc iem: - Day ai ch san pham gii han 10lbs/ft
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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

- Quat s dung yeu cau nang lng cao - Kho khan trong qua trnh ong goi t ong khi nang suat cao - Chi ph bao dng cao( chi ph day ai =35% tong chi ph may)

Hnh 15: thiet b lam cng bang day chuyen xoan oc. f) Lam cng bang phng phap s dung cac khay gia chuoi lien tuc (Tray between continuos chain): u iem: - Thiet b n gian nhat so vi thiet b lam cng bang phng phap lam cng bang oi lu khong kh san pham loai khay - S di chuyen dong oi giup qua trnh lam cng hieu qua hn - Chi ph au t va phai - Lam cng ong thi cac san pham kch thc khac nhau - S ton that trong qua trnh lam cng rat t - He thong khong kh hoat ong hieu qua nen tiet kiem nang lng va giam chi ph - He thong nho 250GPH Nhc iem: - Toc o vat lieu:2500GPH - Khong thch hp cho san xuat ong thi nhieu day chuyen - Chi ph bao dng cao hn so v phng phap tray/transport type systems

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Hnh 16: Thiet b lam cng Tray between continuos chain g) Lam cng bang phng phap thi gian lu bien oi Varible Retention Time(VRT) u iem: - Cho phep thay oi thi gian lu san pham vi he thong co kch thc khac nhau - De dang hoat ong vi cac day chuyen t ong - Lam cng ong thi cac san pham kch thc khac nhau - Toc o san xuat cao (tren 10000 GPH) Nhc iem: - Chi ph cho cac khay cao - Chng trnh van hanh phc tap - Yeu cau ap suat cao, khong thay oi, nang lng cao - He thong kch thc nho khoang 1500GPH - Chi ph bao dng cao

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Hnh 17: Thiet b lam cng VRT h) Lam cng bang cach van chuyen nhieu khay: u iem: - He thong khong kh dong oi giup lam cng tot hn - Chi ph bao tr thap vi th gian s dung lau (tren 30 nam) - He thong khong kh hieu qua giam chi ph va nang lng - Lam cng ong thi cac san pham kch thc khac nhau - Thiet b n gian nhat so vi thiet b lam cng bang phng phap oi lu khong kh san pham loai khay - Chi ph au t va phai - He thong 10000GPH Nhc iem: - He thong phc tap hn so vi - He thong day ai xoan - He thong nho nhat 750GPH

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Hnh 18: Thiet b lam cng bang cach van chuyen nhieu khay Qua trnh tao hnh: a) Thiet b tao hnh cho kem que: Qua trnh tao hnh cho kem que co 2 giai oan: Giai oan phan chia nguyen lieu: nguyen lieu co dang ong dai va c cat thanh tng thanh (bar) co kch thc phu hp. Kch thc cua cac thanh co the c ieu chnh bang toc o chay cua bang tai va tan so hoat ong cua dao cat. Co 2 dang phan chia: theo chieu ngang (Horizontal etrusion) va chieu thang ng ( Vertical etrusion).

Hnh 19: Thiet b ep un ngang

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Hnh 20: thiet b ep un ng.

Hnh 21: Thiet b tao hnh lam cng ket hp Giai oan tao hnh cho cac phan nho: cac phan nho c may ep khuon nh hnh thanh cac hnh dang a dang nh hnh que, hnh thu vat

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

b) Thiet b tao hnh cho kem conerto: Corneto la kem c rot trong banh xop (cone). Quy trnh tao kem conerto khong can may phan chia nguyen lieu hay may ep khuon, ch can may rot kem. Nguyen tac hoat ong cung gan nh may rot kem hop.

Hnh 22: Thiet b rot kem conerto vi 8 au rot. Thiet b tren co the rot cung luc cho 8 banh cone. Moi ong rot kem cho mot banh cone co nhieu ong nho ben trong, moi ong nho c nap nhieu loai kem, chung khac nhau ve mau sac, mui v. Khi c bm en au ra cac loai kem nay se hoa quyen lai vi nhau, tao cho san pham co hnh thc rat bat mat vi nhieu lp kem xem ke. Hnh dang kem a dang con c tao ra bi au phun, cac au phun khac nhau se tao ra hnh dang kem khac nhau, v du nh hnh xoan oc, hnh vo so, hnh thap

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Hnh 23: Mot so loai au phun va san pham cua no 3) Thiet b tao lp ao chocolate Thiet b tao lp ao chocolate bao gom mot bon cha chocolate c pha vi mot so cac nguyen lieu phu khac nh au phong, hanh nhanKem cay sau khi c tach khuon, a qua bon cha dung dch chocolate 40oC e tao ra mot lp ao chocolate cho san pham roi c a vao thiet b bao goi.

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Hnh 24: Cac que kem c ao chocolate, hoac 1 lp mau cam.

Hnh 25: Day chuyen phan chia, ep khuon, gan que va bao ao chocolate IV. SAN PHAM 1) Bao quan: Kem thanh pham c bao quan trong phong lanh -30oC, do ac thu rieng ve cau truc, kem thanh pham can c bao quan trong ieu kien ung quy nh e tranh nhng bien oi va h hong ve mat chat lng. Tai c s san xuat, nhiet o bao quan la -30oC. Kem c van chuyen bang xe lanh 25oC t nha may en ni phan phoi va tieu thu. Ngi tieu dung nen tr kem nhiet o khong ln hn -18oC.

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

Neu nhiet o tang cao khi bao quan, se lam cho lp kem be mat chay ra, gay bien dang san pham va anh hng en cau truc cua kem. Khi ta tien hanh lanh ong tr lai, mot phan ng lactose trong sa co the b ket tinh, va ngi tieu dung se cam nhan c cac tinh the nay khi s dung kem. Bao quan ung quy nh, thi gian bao quan co the keo dai t 6-9 thang. 2) anh gia chat lng san pham: Ch tieu cam quan: san pham gi nguyen hnh dang, mau mui v ac trng. Ch tieu vi sinh: ham lng cac vi sinh vat gay benh nh Samonella, Listeria, Staphyloccoccus aureus khong ln hn 10 khuan lac/ml san pham. Ch tieu hoa ly: ham lng protein, lipid, glucid tong, lactose, o am, ham lng khoang, vitamin dao ong trong mot khoang ln phu thuoc vao dang san pham va quy nh chung cua moi nc. 3) Cac dang san pham kem: Viet Nam: Th phan kem Viet Nam c phan chia nh sau: Kidos chiem th phan cao nhat 45,8%, tiep en la Vinamilk 20,8%, Thuy Ta la 20,8% Tai TPHCM, kem Ki Do dan au vi th phan hn 50%, ng th 2 la Vinamilk 40% va th 3 la Monte Rosa 8%. th trng kem trung va cao cap, Kidos chiem hn 60% th phan. Hien tai, chuyen phan khuc th trng kem vi cac ten tuoi ln a kha ro rang, vi nhng u the rieng. Vinamilk ang co u the ve cac loai kem hop, kem mang ve nha, Monte Rosa lai co u the ve nhom kem cao cap ban he thong ca hang, con Kidos vi 2 nhan hieu Merino va Kidos Premium lai co v the dan au mang th trng kem cay.

San pham kem Vinamilk + Kem sa 2500vnd/cay, hng chocolate, au phong va kem vani + Kem ly Dino 100ml 3000 vnd/ly, cac loai: dau, sau rieng, vani, chocolate, com, trai cay, khoai mon, ca phe, au xanh, da. + Kem cao cap Vinamilk hop 450ml 15000vnd/hop, 26000vnd/hop loai 1l co cac loai: dau, sau rieng, vani, chocolate, com, trai cay, khoai mon, ca phe, au xanh, da.
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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

San pham kem Kido Hien nay, KIDOS ang co 2 nhan chnh la Merino va Kidos Premium vi hn 36 san pham, trong o co 16 san pham mi so vi kem Walls gom cac chung loai: kem hop, kem hu, kem banh va kem que. Cac san pham kem rat a dang gom: Kem Xoai, Kem Mang cau ben canh nhng khau v quen thuoc cua quoc te nh: Kem Chocolate, Kem dau va kem Vani. Nc ngoai: San pham kem cay

San pham kem hop

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Quy trnh va thiet b san xuat kem

GVHD: Thay Le Van Viet Man

San pham kem conerto

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GVHD: Thay Le Van Viet Man

TAI LIEU THAM KHAO

1. Nhat An, Viet Hoa, ng vao nghe-Cong nghe thc pham, NXB Tre, 2007. 2. Le Van Viet Man, Cong nghe san xuat cac san pham t sa, tap1, NXB H Quoc gia TPHCM, 2004 3. Robert T. Marshall, H. Douglas Goff, Richad W.Hartel, Ice Cream, 6th edition, Kluwerr Academic/Pleum Publishers, May 2003. 4. Tetra Pak, Dairy Processing Handbook, Published by Tetra Pak Processing Systems AB, S-221 86 Lund, Sweden. 5. www.whiteysicecream.com.facility.asp 6. www.florenceicecream.it/index.htm 7. www.tcpionneer.com.tw.products03.htm

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