Ice Cream - Production

Production

Before the development of modern refrigeration, ice cream was a luxury reserved for special occasions. Making it was quite laborious; ice was cut from lakes and ponds during the winter and stored in holes in the ground, or in wood-frame or brick ice houses, insulated by straw. Many farmers and plantation owners, including U.S. Presidents George Washington and Thomas Jefferson, cut and stored ice in the winter for use in the summer. Frederic Tudor of Boston turned ice harvesting and shipping into a big business, cutting ice in New England and shipping it around the world.

Ice cream was made by hand in a large bowl placed inside a tub filled with ice and salt. This was called the pot-freezer method. French confectioners refined the pot-freezer method, making ice cream in a sorbetière (a covered pail with a handle attached to the lid). In the pot-freezer method, the temperature of the ingredients is reduced by the mixture of crushed ice and salt. The salt water is cooled by the ice, and the action of the salt on the ice causes it to (partially) melt, absorbing latent heat and bringing the mixture below the freezing point of pure water. The immersed container can also make better thermal contact with the salty water and ice mixture than it could with ice alone.

The hand-cranked churn, which also uses ice and salt for cooling, replaced the pot-freezer method. The exact origin of the hand-cranked freezer is unknown, but the first U.S. patent for one was #3254 issued to Nancy Johnson on September 9, 1843. The hand-cranked churn produced smoother ice cream than the pot freezer and did it quicker. Many inventors patented improvements on Johnson's design.

In Europe and early America, ice cream was made and sold by small businesses, mostly confectioners and caterers. Jacob Fussell of Baltimore, Maryland was the first to manufacture ice cream on a large scale. Fussell bought fresh dairy products from farmers in York County, Pennsylvania, and sold them in Baltimore. An unstable demand for his dairy products often left him with a surplus of cream, which he made into ice cream. He built his first ice cream factory in Seven Valleys, Pennsylvania, in 1851. Two years later, he moved his factory to Baltimore. Later, he opened factories in several other cities and taught the business to others, who operated their own plants. Mass production reduced the cost of ice cream and added to its popularity.

The development of industrial refrigeration by German engineer Carl von Linde during the 1870s eliminated the need to cut and store natural ice, and, when the continuous-process freezer was perfected in 1926, commercial mass production of ice cream and the birth of the modern ice cream industry was underway.

The most common method for producing ice cream at home is to use an ice cream maker, in modern times, in general, an electrical device that churns the ice cream mixture while cooled inside a household freezer, or using a solution of pre-frozen salt and water, which gradually melts while the ice cream freezes. Some more expensive models have an inbuilt freezing element. A newer method of making home-made ice cream is to add liquid nitrogen to the mixture while stirring it using a spoon or spatula. Some ice cream recipes call for making a custard, folding in whipped cream, and immediately freezing the mixture.