At FFCE, we provide end-to-end assistance for the production of soft-serve ice cream, a popular treat known for its smooth, airy texture and creamy consistency. Soft serve requires specific techniques and equipment to achieve its characteristic light and airy texture. Our role is to ensure your soft serve meets consumer expectations for both taste and quality.

We start with the pre-production part which includes sensory evaluation and recipe formulation, proper project ideation, Licensing, and Permitting Assistance, Documentation Preparation and Management, and market research. Then we focus on the production part which includes, implementing the latest technology for critical steps like mix preparation, freezing, and dispensing. Proper emulsification and homogenization are essential to create a smooth base. Which is then carefully frozen to incorporate just the right amount of air, giving soft serve its signature lightness. Then take care of the post-production part which includes packaging, third-party manufacturing, legal assistance if needed and focusing on commercialization of the product if required. 

What is Soft Serve Processing?

Soft-serve ice cream is made by blending milk, sugar, and flavorings into a smooth mixture. This mixture is then pasteurized to ensure safety and uniformity. After pasteurization, the mix is homogenized to break down fat molecules, which helps create a creamy texture.

The mix is then placed in a specialized soft serve machine where it’s churned and frozen at a temperature slightly warmer than regular ice cream, allowing more air to be incorporated. This results in the soft, smooth texture that soft serve is known for. The final product is dispensed directly from the machine into cones or cups, ready to be enjoyed immediately. Careful control of the freezing process is crucial to maintaining the soft, airy consistency that consumers expect from high-quality soft serve.

The main equipment used in soft-serve ice cream production includes mixing tanks for blending ingredients, a homogenizer to reduce fat globule size, and a pasteurizer to ensure food safety by eliminating harmful bacteria. Aging tanks cool and store the mix to develop stabilizers, while a soft serve freezer machine freezes and churns the mix, incorporating air supplied by an air compressor to create a light, creamy texture. The dispensing unit releases the soft serve directly into cones or cups, and cleaning and sanitization equipment ensures the machinery meets hygiene standards throughout the process.

Types of Soft Serve Ice Creams

Soft-serve ice creams come in various flavors and styles, catering to different taste preferences. Here are some common types:

  • Classic Flavors: Vanilla, chocolate, and swirl (a combination of vanilla and chocolate).
  • Fruit Flavors: Strawberry, mango, blueberry, and other fruit-based options.
  • Specialty Flavors: Coffee, matcha, or seasonal flavors.
  • Dairy-Free Alternatives: Soft serve options made with plant-based milks such as almond, soy, or coconut.

The Production Process of Soft Serve Ice Creams

The production of soft-serve ice cream involves several key steps to ensure the final product is smooth, creamy, and of high quality. Here’s a detailed overview of the process:

  1. Ingredient Selection and Sourcing
    Objective: Choose high-quality ingredients to ensure a superior product.
    Process:

    • Milk and Cream: Use high-fat content milk and cream to achieve a rich, creamy texture. The fat content typically ranges from 3-6%.
    • Sweeteners: Select granulated sugar, corn syrup, or other sweeteners to achieve the desired sweetness and consistency.
    • Stabilizers and Emulsifiers: Use stabilizers like guar gum or xanthan gum and emulsifiers like lecithin to improve texture and prevent ice crystal formation.
    • Flavorings: Incorporate natural or artificial flavorings to create diverse flavor profiles.
    • Water: Purified water is used to adjust consistency and blend with other ingredients.
  2. Mixing and Pasteurization
    Objective: Create a uniform mix and ensure safety.
    Process:

    • Mixing: Combine milk, cream, sweeteners, stabilizers, emulsifiers, and flavorings in precise proportions. Mix thoroughly to achieve a smooth, homogeneous mixture.
    • Pasteurization: Heat the mix to 85°C (185°F) for 30 minutes or to 90°C (194°F) for 10 minutes to kill harmful bacteria. Rapidly cool the mix to 4°C (39°F).
  3. Freezing and Aeration
    Objective: Achieve the desired semi-frozen texture with proper aeration.
    Process:

    • Freezing: Transfer the pasteurized mix to a soft serve machine. Freeze the mix while incorporating air (overrun) to achieve a light, smooth texture. The freezing temperature is maintained between -6°C and -8°C (21°F to 18°F).
    • Aeration: The mix is aerated during freezing to incorporate air, resulting in a light, fluffy texture.
  4. Dispensing and Storage
    Objective: Serve the ice cream at optimal texture and maintain product quality.
    Process:

    • Dispensing: Serve the soft serve directly from the machine into cones or cups. The texture is smooth and creamy, suitable for immediate consumption.
    • Storage: Any remaining ice cream in the machine is kept at -18°C (0°F) or lower to prevent melting and maintain texture.
  5. Packaging and Labeling
    Objective: Protect the product and provide consumer information.
    Process:

    • Packaging: For bulk distribution, use containers made of food-grade plastic or glass. For single-serving options, use paper cups or cones. Packaging must be airtight to prevent contamination and freezer burn.
    • Labeling: Include nutritional information, ingredient lists, and expiration dates. Labels should be durable, waterproof, and clearly display all necessary product details.

Engineering of Packaging Materials for Soft Serve Ice Creams

Packaging is crucial for maintaining the quality, freshness, and appeal of soft-serve ice creams. Selecting the right packaging materials ensures product protection, convenience, and consumer satisfaction. Here are the key types of packaging materials used:

  1. Bottles and Jars
    Objective: Provide durable, resealable options that maintain product freshness.
    Materials:

    • Glass: Offers excellent protection against external contaminants and maintains the pure taste of the ice cream. Recyclable and eco-friendly.
    • PET (Polyethylene Terephthalate): Lightweight, shatterproof, and provides good barrier properties. Recyclable and comes with tamper-evident seals.
  2. Pouches
    Objective: Offer a lightweight, portable, and convenient packaging option.
    Materials:

    • Multi-layer Laminated Films: Provide excellent protection against light, air, and moisture. Spouts allow for easy pouring and resealing.
    • Stand-up Pouches: Ideal for powdered soft serve mixes, providing stability and minimizing packaging material usage.
  3. Cans
    Objective: Provide a single-serving, easy-to-chill packaging option.
    Materials:

    • Aluminum Cans: Lightweight, durable, and offer strong barrier properties. Easily recyclable with protective linings to prevent interaction between the metal and the product.
  4. Sustainability
    Objective: Minimize environmental impact and appeal to eco-conscious consumers.
    Sustainable Practices:

    • Recyclable Materials: Use materials like glass, aluminum, and PET, which are widely recyclable.
    • Reduced Packaging Weight: Design packaging that uses fewer materials while ensuring product protection.
    • Biodegradable Options: Explore biodegradable materials such as plant-based plastics or paper-based alternatives.