Troubleshooting: Finding/correcting deviations from normal

Ice cream and related products are both special (i.e., the only foods designed, formulated, processed, packaged, stored, distributed, and offered for sale with the express intent of being consumed frozen) and among Mother Nature’s most complex food products. This is particularly true when working to consistently deliver the same quality and quantity of products verses some defined set of consumer expectations and/or finished product specifications.

Consider all the possible variations that can and most likely will, at some time, deviate from expectations verses some defined set of “normal” (i.e., finished product specifications.) Thus, the number of variables affecting functional, safety, and sensory properties, and, ultimately, acceptability of any given ice cream at any given time, are immeasurable, involving, at a minimum, the intricacy and interactions of individual ingredients, mechanics of ingredient functional development (and interactions thereof), mix assembly/processing, flavoring/coloring, whipping/freezing, packaging, hardening, and, expectant resistance to heat shock through the entire intended shelf-life of the finished ice cream. All of this governed by Mother Nature’s rules of chemistry and physics.

Steven Young, Ph.D., is principal, Steven Young Worldwide; Bill Sipple is principal, Wm Sipple Global Services.

When deviations and issues do arise, a general/focused approach to troubleshooting helps. Note the following…

Identifying and Defining “Normal,” which should be part of a Product Brief that aligns with marketing, sales and general business objectives.

Using a Standard Operating Procedure (SOP). Research and development should always initiate expected processing and quality parameters so that the factory understands what is expected. Many times, R&D hands off a new product without providing adequate (even inadequate) and subsequential factory start-up assistance.

Sources of variation

At each step of the design, formulation, manufacture and sale of ice cream products consider the basic sources of variation:

• Manpower: e.g., differing personnel; shift/shift changes, capabilities/training.
• Materials: e.g. commodities, and other ingredients, purchased from differing suppliers with similar specifications but differing functionalities. Understanding the effects of ingredients, in relation to packaging on finished product quality across storage and distribution.
• Methods (approaches): differing approaches to standard methodologies; is the approach(es) accurate (are you doing what you intended to do?) and precise (repeatable?)
• Machines: Differing machines and/or operating parameters; differing locations within a plant; perhaps, differences across multiple manufacturing sites within the same organization?

Where deviations from “norm” are more likely:

• Ingredients: Alternative suppliers with similar specifications but differing functionalities.
• Formulation: Routine and/or frequent formula changes seeking cost reduction and/or cost avoidances.
• Mix Making: New operators, refurbished/redesigned equipment, equipment malfunctioning, misused, or not used at all.
• Whipping/Freezing/Hardening: Seasonal factory temperature changes with corresponding refrigeration capacity issues/considerations.
• Packaging
• Novelties (molded, filled, extruded; primary (overwrapping) secondary (boxes) tertiary (cases/pallets).
• Packaged ice cream (pints, ½ gallons, bulk; tamper evident(?).
• Distribution, storage, point-of-sale, points of consumption/use.

Not to be forgotten: Things can get complicated, and detailed, very, very quickly, so care is necessary when troubleshooting and bringing any deviation back to “normal.”

Ultimately, will the specific ice cream, or any other frozen dessert, meet or exceed consumer/customer quantitative and/or qualitative expectations? Not easy but issues probably will arise. Be prepared and enjoy a study of a lifetime! DF