In the list of things that give joy to the soul, ice cream is right up there, just behind love, laughter, and well, more ice cream. Throughout history, these cold, melting dollops of deliciousness have held a cherished spot in the hearts of children and adults alike. Even as they have evolved in form and variety over the centuries, this affection remains unchanged.Even with all this ice cream love going around, very few people really know how ice creams are really made. So we have to set out to tell you this tale and unravel the mysteries behind the great and joy-filled art of ice cream making.While we can’t speak for others, we assure that what follows is an honest overview of the ingredients, processes and quality measures we use to make our much loved brands of ice creams.
THE INGREDIENTS FOR OUR DELICIOUS NATURAL DELIGHTS
Lazza Ice Creams are made from naturally-sourced raw ingredients.We use high-quality flavouring from reputed national and international brands.Food colouring is kept within 200 units PPM as per standards.Soon, we will be switching to natural pulp and naturally extracted essences exclusively for our Lazza brand of products.
7 STEPS TO MAKING MAGIC
There is a lot of love, care and expertise that goes into making your little scoops, lollies and cones of magic. Let’s have look at how we make this happen.
1. Assessing Requirements/Material Issue
We have an automatically generated internal program that decides the production requirements of the day. The corresponding raw materials and packing materials are automatically issued to the factory floor based on this.
2. Pasteurization Hoppers
All the ingredients like skimmed milk, milk, sugar, butter etc. are first added into two large pasteurization hoppers. These hoppers are maintained at 75 degrees to achieve pasteurization and kill any microbial organisms.
The pasteurized mix moves into the homogenizer. The homogenizer applies 2,500 PSIs of pressure to mix the ingredients thoroughly. It ensures that the various ingredients in different forms and states don’t stand out separately or in layers.
4. Cooling & Chilling
The mix now moves into the cooling and chilling section. This is built up of rows of metal plates.Cold water is passed through alternate plates to cool the mixture from 75°C to 10°C.
5. Ageing Vats
The mixture finally moves into the ageing vats. These are collection tanks where the mixture is stored for a period of 8 hours. Here, the temperature is brought down by 1°C every hour until the mix is at 4°C. This is necessary to bring out the taste of the ice cream.
6. Ice Cream Machines
From the vats the mix is pumped into the ice cream making machines. Flavouring and colouring are added through the servo tanks placed above the machines. The final product comes out at -4°C. This is sent down the conveyor belts, and packed.
7. Cold Room
The cartons of ice cream packs are sent to the cold room to be stored at -25 degrees in hard form before they are transported to the distributors.
QUALITY ABOVE EVERYTHING
For us, quality is not an objective, but a habit. It is one of our core principles, guiding us through all that we do. This habit pervades the organisation’s culture, and has enabled us to consistently deliver high-quality international-standard products to our customers for nearly 50 years.To begin with, we only use ingredients that are certified and approved by FSSAI (Food Safety and Standards Authority of India). Our factories are HACCP and ISO 22000:2005 certified, and we take strict measures to ensure plant hygiene and product quality.We maintain unwavering standards of quality across three critical control points – biological, chemical, physical. Here’s how we ensure this –
● HACCP codes established across our factory floors
● Separated storage sections for packing materials, containers etc.
● Factory floors isolated from all external elements – people, dust etc. to prevent cross contamination
● Strict hand-washing with disinfectant every 20 minutes for workers in regular contact with the ice creams
● Multi-level supervision over processes, men and materials
● Quality control and check on all ingredients and incoming materials before production
● In-house lab for frequent quality checks and tests
● Detailed 5-step backwash process at the end of each production day using hundreds of litres of water and high quality, food grade chemicals
TRACING OUR STEPS FORWARD
We are big believers in accountability. And one of the major ways that we ensure this is by implementing solid accountability measures across our products and processes.In accordance with HACCP recommendations, we maintain a total of 17 logs. These include the production log, workers' hygiene log, daily sanitation log, online product verification log etc. Every batch of products has a unique batch code that can provide information about quantity and details about the product, the factory and date of production, the supervisors and workers on the factory floor at the time, and much more.
These measures help with backtracking from any point of damage or complaint to find out the exact junction where we went wrong. Following this, we can take corrective measures or even issue recall, as required.
We really hope that this brief look at how we make the ice creams you love so much has helped you gain a better perspective about Lazza and our ice creams in general. In addition to everything above, there is a lot of care, dedication and passion that goes into creating these extraordinary ice cream experiences, to ensure that you, your family and your kids can enjoy them without ever having to worry about the health effects.