04_How It's Made Ice Cream Treats
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Before refrigeration, ice-cream was a hand made luxury,
ingredients went into a mixing bowl,
inside a tub filled with ice and salt water.
The salt help the ice absorb heat,
cooling the mixture to below freezing.
In the 1920s, commercial freezers made mass production possible
and the ice-cream industry was born.
To make ice-cream treats,
you first have to make the ice-cream.
It all begins with fresh cream.
The factory stores it in the refrigerated
silos set just a few degrees above freezing.
The silos be the high speed mixer
that blends the cream with other ingredients.
The main dry ingredients are powdered skim milk and
plant base stabilizers and emulsifiers.
Stabilizers prevent the ice-cream from crystallizing.
And emulsifiers allow the mix to bond with air
during the whipping process.
The other ingredients are sugar and corn syrup.
After about 3 minutes of mixing,
a pumping system moves the mixture
into a pasteurization tanks and heats it to a
hundred and sixty-two degrees for half an hour,
killing any bacteria and activating the stabilizers.
Then, the factory homogenizes the mixture
a process that breaks up the fat globules
giving the ice cream a smooth texture.
The mixture is cooled and concentrated
with a lil flavoring is added.
Then, the concoction is chilled
and wiped for about 15 seconds,
wiping blends the mix with air
transforming it from a liquid
to a soft solid.
Without air the finished product,
would come out looking like
frozen milk rather than ice-cream.
The ice-cream sandwich wafers
are made of chocolate cake ingredients.
A filling machine feeds two lines of wafers
toward an injection pipe.
Just as two wafers come together
the machine adjust third of a cup of vanilla ice-cream
in between.
The pipes edge shapes the ice-cream
into a rectangular slab
that it fits perfectly between the wafers.
All this happens at a rate of
140 ice-cream sandwiches per minute.
As the sandwiches move on to
packaging the filling is still ice cold
from the freezing phase.
So, there's no threat of a melt down.
The packaging system raises
each sandwich into a wrapper
then fold and tucks the ends.
The next machine counts the sandwiches
and inserts them in the boxes.
Once sealed, the boxes go directly
into a storage freezer at minus 22 degrees.
On another line,
ice cream cone production is underway.
A feeder drops pre wrap sugar cones in
the holders on container belt.
Sprayers coats the insides with chocolaty layer,
which adds a flavor and creates a barrier between
the cone and ice-cream.
So, the cone remains crispy
until you eat it.
Next, nozzles squirt in the ice-cream filling.
One production line, two flavors.
One row of cones gets vanilla ice-cream
the other row chocolate.
Now, for tasty surprise
in the cones core
an injection of liquid caramel
This factory also makes ice-cream cones with chocolate
and strawberry sauce inside.
Next, a chocolate flavored liquid topping.
Then the crunchy finishing touch
a layer of chocolaty coated puffed rice.
Finally, the cones move under a lid dispenser
that applies a wax coated paper
lid to each one.
A heating element instantly melts the wax
ceiling the lid the cone's paper sleeve.
From here, the ice-cream cones
go into boxes.
Then, straight into the freezer,
ready to take a licking.