Well qualified manufacturing team, all proceedings defined in manuals and constant quality supervision ensure the high and consistent quality of our products.
We always buy raw materials, half products and packaging materials from the same, reliable and constantly verified suppliers. Receiving the supply is one of the most important stages of production – the quality of the finished product is determined by the quality of intermediate products. All raw materials, half products and packaging materials are subject to inspection before they are accepted. The received products undergo physicochemical, microbiological and organoleptic inspection. For the inspection process we use the highest quality measuring apparatus, i.e. Milkoskan, which can assess all the parameters of a given raw material or half product ( i.e. fat, proteins, sugars or dry matter in milk) with high accuracy in only few minutes. If the supplied goods do not meet the demands included in the facility specifications they are sent back to the supplier.
Every stage of the manufacturing process is under constant supervision by the Quality Control Department. Preparing the ice cream mixture is a very important link in the manufacturing process as it determines the quality of the finished product. A laboratory technician working for the Quality Control Department performs the physicochemical and organoleptic assessment of every ice cream mixture following the requirement specified in the recipe. Mixture samples are send to a laboratory via an air conveyor for a full analysis by a Milkoscan and colorimeter.
After being approved, the ice cream mixture is pasteurized. The parameters of this process, along with all the peripherals, are being monitored by a data logger and a team of operators. The whole process is supervised by production workers and laboratory technicians.
Then, after a heat treatment, the mixture is send to a ripening tank where it is left for a controlled ripening process. Workers of the Quality Control Department make sure that the time and temperature of this process are just right.
When the mixture has been initially frozen and aerated in a controlled temperature, all the additional ingredients (nuts, raisins) are added, and the ice cream is finally moulded. The amount of additional ingredients must be exactly as specified in the recipe and the appearance of the ice cream must correspond to its sample model. Both the Manufacturing Department and the Quality Control department supervise the last processes of the production that is: packaging, dating or palleting.
Finished product inspection
Each lot of the finished product is subject to physicochemical, microbiological and organoleptic analysis and all the results are included in the control charts. Designated workers from the Quality Control Department asses the appearance and taste of randomly chosen samples of each produced lot. The organoleptic parameters of the product must be consistent and compliant with the standard. Additionally, the Quality Control Department takes retention samples of each produced lot. Sampling enables constant control over the quality of the product during its shelf life and provides reference marks to each produced lot.
Storage and distribution
Storage is also a controlled process. Storage conditions are monitored and registered and the FIFO (first in, first out) rule is applied. Each of the finished products possess markings that enable the recreation of the history of a given product. Storage documentation helps to control the product during its distribution.
Distribution is one of the most important stages of the production process, and as such it must be well organized and controlled. All the effort put into the technological process may be ruined if the distribution stage is neglected. The whole distribution network, along with the sale and presentation of the ice cream should be controlled in order to ensure the right conditions of the storage. Ice cream should not be exposed to any temperature fluctuations (temperature shocks) during storage and distribution as it may have negative effect on the texture of the ice cream. With the rise in temperature, small ice crystals melt more easily than large crystals. When the temperature drops down again, the water freezes around the bigger crystals which makes them even larger (a so called recrystallization).This phenomenon has a direct negative effect on ice cream – they lose their “smoothness”. Moreover, temperature fluctuations during storage and distribution may cause lactose crystallization – ice cream becomes grainy, it is reduced in size and is no longer rich and smooth.