Kemps Ice Cream Shop Manual

Our Goal for you:

To have the BEST customer service, the BEST ice cream, and the BEST ice cream store, providing the
BEST overall experience through quality, fun, and unique frozen desserts!

Kemps Purpose: We nourish families

• By providing wholesome dairy products that nourish families and promote happiness

• Through the support we provide each other as a family of employees

• Through the engagement of our employees in the communities we serve

• Through the return we provide for our farmer owners and their families

A tradition of FRESHNESS

From our beginnings as a small creamery in southeastern
Minnesota, Kemps has extended its roots to include the
manufacture and marketing of fresh milk, premium ice
cream and frozen yogurt, frozen novelties, sour cream and
cottage cheese in both retail and food service channels.

Our goal in food service is to listen to our customers
and respond by providing the best tasting, highest-
quality products.

What makes Dairy Farmers of America so special? Our
13,000 dedicated family farmers who work tirelessly across
the country. We’re proud to call ourselves 100% farmer
owned, and recognize that wholesome fresh dairy is the
source of our Kemps quality products.

A tradition of QUALITY

As a result of FDA’s finalization of the Food Safety Modern-
ization Act (FSMA) and the recent events surrounding the
ice cream industry, Kemps has evaluated all food safety
and quality aspects of our internal programs and are in the
process of strengthening all protocols to build towards a
best in class facility.

Kemps environmental testing program (zones 2-4) has
been enhanced over the last year in terms of number of
swabs completed.
We have initiated a very controlled process of zone 1 swab-
bing and finished product testing on a weekly basis (as of
September 2015).
In order to maintain a controlled hold process while zone 1
and finished product tests are pending, our positive release
program has been expanded to roughly 96 hours in our ice
cream facility.
Our definition of a lot code has been improved to narrow
the amount of “in process” product that is carried between
production days.
Kemps has enhanced our cleaning schedule and sanitation
equipment over the past year. The schedule we maintain
for sanitation requires the entire filling room to be cleaned
and released for production as a full unit.

Contents

What is ice cream_______________________________________________________ 1
Ice cream at Kemps _____________________________________________________ 1-2
Ice cream components ___________________________________________________ 2
Choosing the right ice cream ______________________________________________ 3
Basic operator inventory/supplies___________________________________________ 4
Opening your doors for business ___________________________________________ 5-6
Tools of the trade _______________________________________________________ 7-8
Daily To Do’s __________________________________________________________ 9
Soft Serve ____________________________________________________________ 10
Commonly Asked Questions ______________________________________________ 11
Glossary of Terms ______________________________________________________ 12

What is Ice Cream?

By definition Ice cream is a food produced by freezing, while stirring, a pasteurized mix of dairy that may
contain one or more flavors, inclusions, and revels. By USDA standards Ice creams standard of identity
contains a minimum of 10% milk fat and 20% total milk solids before the addition of flavors, revels, candies,
nuts, etc. One gallon must weigh at least 4.5 pounds and contain not less than 1.6 pounds of food solids.
Common associated products to the ice cream family are listed below:

Reduced Fat/Low Fat/Light Ice Cream/Frozen Dairy Dessert

• Frozen dairy with less than 10% butterfat.

Sherbet

• A frozen dessert made with fruit juice added to milk or cream, egg white, or gelatin.

Gelato

• Similar to ice cream but typically 5-9% butterfat with a denser, less airy texture.

Frozen Yogurt

• Typically assumed to be a healthier version of ice cream but uses cultured milk and typically very
little cream. Frozen yogurt is most commonly found in Low-fat and Non-fat varieties and will have a
tarter taste profile.

Ice Cream at Kemps

Ice cream manufacturing at Kemps starts with fresh ingredients delivered daily from local Midwest dairy
farmers. Manufactured in Rochester, MN we pride ourselves at not only using local Midwest dairy farmers,
but proud to say that many of our suppliers are also DFA member/owners. Our parent company DFA has
8,500 dairy farms and offers us the support to continue to develop new and unique flavors while keeping
the highest safety standards in place at our manufacturing facility.

The process all begins with fresh cream. Other ingredients such as fruit, candy, nuts, and even spices are
processed under stringent food safety guidelines before the freezing process even begins. These are then
all combined with just the right amounts into mixing tanks. When everything is just right the product is
pumped out to begin the freezing process that results in the ice cream served at your favorite location
throughout the US.
1

Those ingredients are pumped into freezing cylinders that contain rotating blades that keep ice off the sur-
face and dashers, perpendicular blades with fins, which incorporate air into the mix. The characteristic
lightness of ice cream is the result of the introduction of air, called overrun. Overrun gives ice cream that
smooth rich finish allowing you to enjoy across your entire pallet. Without overrun, ice cream would have
the consistency of an ice cube. After half of the ice cream batch is frozen, additional inclusions such as
fruits or nuts are added to the semi-frozen slurry, which has a consistency similar to soft serve. The ice
cream is pumped through lines into packaging and the packages of ice cream are placed in a freezer at -30
to -40°F where the remainder of the is rapidly frozen. Below -25°F ice cream is stable for indefinite periods
without danger of ice crystal growth, also known as shrink. Above this temperature ice crystal growth will
limit shelf life and can affect overall customer satisfaction.

Ice Cream Components

Ice cream is typically compared to other ice creams by many features, such as, taste, color, and even
smell. While these features can be important, there are 3 factors that can help to cut through the clutter
and assist in making final decisions in your ice cream business.

Butterfat:

• Also called milkfat, butterfat is the cream portion of the ice cream. Butterfat helps determine the way
it coats your palate, the density of the final product, the richness of product, and finally the caloric
value of the ice cream.

• Butterfat alone does not determine the quality of the ice cream and can many times be inappropri-
ately used to determine purchase.

Overrun:

• Overrun is the amount of air that is incorporated into the ice cream making process. Typical ranges
of overrun are 60-100%. Air is an important part of ice cream for scooping, yield, and overall mouth-
feel and texture.

Flavors: (Ingredients/Inclusions)

• The sky can be the limit when it comes to ice cream flavors. The most important factors that go into
a flavor creation are the ingredients/inclusions that may be found in the ice cream. Inclusions can
be defined as any pieces that are stirred into ice cream to give it a unique texture, taste, or visual
appeal. A flavor enhancing ingredient can be something as simple as vanilla, or as complex as a
caramelized melody of fruits and aromas.

• Flavors can be one of the single biggest factors to look for when deciding on an ice cream and it’s
rotation in your case. A premium processed ice cream will not only have a variety of flavor options,
but will have consistency in production that makes each scoop that goes to the customer similar to
the next scoop.

Did You Know?

The main factor that differentiates hard ice cream from soft serve ice cream is serving tempera-
ture. Soft serve ice cream is typically served between 20-25°F and hard ice cream is best
served between 0-5°F. Soft serve is typically 5% butterfat or lower, but can also be found in
non-fat, high-fat , and frozen yogurt varieties.

2

Choosing the Right Ice Cream

When choosing ice cream for your business, several factors must be taken into consideration. As men-
tioned previously the 3 key factors can assist in decisions. However the following factors will help fine-tune
your flavor rotation when making your selection.

Taste

Ultimately everyone has different opinions and preferences in taste, but let your personal preferences be
your guide while still remaining open to different trends that the marketplace is showing.

Appearances

Take a careful look at the product. Evaluate color, texture, and even the aroma of the ice cream.

Mouth Feel

Scrape a small sample of ice cream and place on your tongue. Roll it around and smack your lips, enjoy
the texture. Like wine tasting, there are many intricate flavors in ice cream. This sampling process allows
you to experience all the variety in a small spoonful.

Price

The cost of ice cream must enable you to meet the food cost target you have established for the dessert
segment of your menu. While pricing should not be the primary focus, in most situations, it is always best
to stay within a budget. In a full service restaurant, desserts are typically very profitable. If ice cream is the
focus of your menu, you may consider sacrificing some margin in the interest of increased volume and cus-
tomer satisfaction.

Consumer Base

It is always best to first identify your key customer base or demographics. If you intend to serve shakes
and other traditional fountain preparations you will probably want a more mainstream product with 10-12%
butterfat and 100% overrun. A rich dessert or bakery base may lead you to higher butterfat ice cream, but
this is extremely rich and is generally best appreciated in small quantities.

Menu Strategy

Adding ice cream can be as simple as purchasing vanilla ice cream and paring it with another dessert or in
a cone. A more involved operator will require investment of time and money by creating a brick and mortar
location that is a ice cream destination. For a menu that’s primarily focused on ice cream you will want to
focus on variety, product consistency, and availability in addition to price.

3

Basic Operator Inventory

Item Description Large Mid-size Small Soft Serve
Dipping Freezer Operator Operator Operator Operator
Cones
Point of Sale 16-32 8-16 4-8
Serving Dishes
Napkins/Utensils 3 varieties 2 varieties 1 variety Cake cones
Nutritionals
Scoops
Spades
Scales
Probe Thermometer
Cabinet Thermometer
Night Covers
Sample Spoons
Cone display/holder
Mixers
Dipper Well
Other Toppings
Flavor Rail
Condiment Holder

4

Opening your doors for business

Costing hard ice cream is straightforward. Determine the weight of each tub of product. The weight of the
tub in pounds, times 16 oz. per pound, equals the weight of the tub in ounces. The cost per tub, divided by
total ounces, equals product cost per ounce. Weight of the serving size in ounces, times the cost of product
per ounce, equals the cost per serving.

Example:

• Tub of ice cream weighs 14.5 lbs. 15 x 16 ounces = 240 total ounces

• Cost of the tub ice cream = $30 ÷ 240 ounces = $.125 per ounce

• 3oz scoop = .125 x 3 = .375 / serving of ice cream

Note: A tub of ice cream will contain 3 gallons of “fluid” ice cream as required by the FDA. Many calcula-
tions use “3 fluid gallons” of product, which would equate to 360 ounces of ice cream. Because of the over-
run factor, the 360 ounce formula gives a distorted amount of finished product and will skew the cost for-
mula.
Portion control is essential to the profitability of every retail ice cream operation. Staff should practice por-
tioning and weighing different sizes of basic fountain items. Remember that appearances can be deceiving;
the only true measure of accurate portioning is weight.
The cost of the ice cream must meet the food cost target you have established for the dessert segment of
your menu. Ice cream either paired with a dessert or served alone is typically very profitable and should
have a target of 25% of total food cost.

Proper Dipping Techniques

Scoops / 3 Gal. Weight of Scoop
132 1 5/8 oz
87 2 1/2 oz
69 3 oz
57 3 3/4 oz

Proper dipping technique is important, not only will it make scooping the ice cream quicker, it will maximize
yield and help with quality control. The following 4 factors will assist you in your overall product yield.

5

Wetting the Scoop:

Dip the scoop into fresh water and gently tap to remove excess water, this can be done on the dipper well
or simply by tapping a clean cloth on the counter. This helps the scoop glide through the ice cream and
helps in maximizing yield. Too much water will leave excess water behind and begin to form ice crystals
affecting overall quality.

Circular Scooping:

Using a sharp edged dipper, cut a ribbon of ice cream, in a circular pattern, working from the outside of the
container inward. When the appropriate amount of ice cream is scooped simply turn the dipper upward and
lift. Using this pattern will minimize the downward pressure on ice cream and allow to gather more ingredi-
ents in one scoop. Continue until the top layer of ice cream is removed from the container and the surface
is level and then repeat.

Grooming:

Using a spade you will need to periodically clean the walls of the tub to prevent ice crystal growth and re-
duce product waste. This is essential when closing for the day, but also a good habit to form just as any
other technique.

Temperature control:

The optimum temperature for dipping ice cream is approximately 0-5°F and will allow for easy scooping of
the product. There are slight variations of product storage based on the ingredients, flavors, and inclusions,
so it is best to use your probe thermometer to test the individual product rather than rely on the cabinet
thermostat.

Freezer Storage

✓ It’s best to check for incoming product quality randomly throughout operation. This can be done visually
by appearance or probe with a thermometer assuring incoming product is transported below 5°F.

✓ Immediately store any excess inventory at 0° to -10° F.

✓ Place all ice cream products on racks for air circulation between stacks and freezer walls, it is best to
store away from the door to minimize warm air exposure when opening and closing the freezer.

✓ A common best practice is to keep the thermometer visible in storage and in the cabinet so you can vis-
ually check temperature.

✓ In a process known as tempering, it’s best to allow ice cream in the cabinet to warm between 0-5°F. 6
This will enhance the flavor and mouthfeel for your customer while allowing easier scooping for
the operator.

Tools of the Trade

Scoops

A good quality ice cream scoop and spade are important invest-
ments. Make sure they have a strong neck that will not bend.
Paying $20 to $30 per scoop or spade is not unreasonable.

Spades

Ice cream spades are used for packing “to-go” ice cream containers
and grooming ice cream. Throughout the day, ice cream should be
“groomed” by using an ice cream spade and scraping down the ice
cream that is left on the sidewalls of tub.

Dipper Wells

Ice cream dipper wells are a must by most inspection agencies. Most must have access to both circulating
water along with a drain. However there are certain models that work by heating the water. They are used
as a sanitary measure to keep your scooping utensils clean from debris and bacteria growth.

Scales/Thermometers

These items do not get used everyday, but are essential for training and store profitability. They will assist
with store profitability and are a key factor in diagnosing any quality issues.

7

Serving

Cones

Sugar Cone Cake Cone Waffle Cone

Dishes

Waffle Bowl Paper or Plastic Serving Cup

Specialty

Sundae Dish Banana Split Boat

Other Toppings

Fruits Nuts Candies Sauces 8

Daily To Do’s

Starting the Day

✓ Check cabinets for cleanliness from night before and clean if needed
✓ Remove night covers
✓ Check cabinet temperature and visual inspection of ice cream
✓ Turn on dipper wells and place clean scoops and spades in water
✓ Take out any back stock inventory that may be needed and place in front of location

• This includes ice cream vacancy’s, sample spoons, cones, etc...
✓ Turn on lights inside cabinet
✓ Check to make sure ice cream is labeled and in correct locations
✓ Open your door and bring in the smiles, check periodically throughout the day for cleanliness

During the Day

✓ Regular grooming when time allows
✓ Refill any product outages
✓ Store & cabinet cleanliness

Closing the Day

✓ Thoroughly clean the outside glass and any interior spills or mishaps
✓ Using your spade groom the tub by turning down excess ice cream on the side walls
✓ Place night covers on ice cream
✓ Wash all scooping utensils, dishwashers not recommended as they may leave calcium deposits
✓ Turn off dipper wells
✓ Check cabinet temperature
✓ Empty any trash for sample spoons, around cabinet, etc…
✓ Turn off cabinet lights and make sure cabinet doors are completely closed

9

Soft Serve Ice Cream

As with hard ice cream, soft serve mix must contain 10% butterfat to meet
the definition of real ice cream. However, soft serve mix with a milk fat con-
tent of 3% to 5% is most common in the industry. Sometimes soft serve mix
can be referred to as reduced fat ice cream or even ice milk.

Soft serve yogurt is a cultured product that is lower in sugar and fat (usually
between 0 and 4%). In nonfat yogurt the fats are removed and replaced with
stabilizers and carbohydrates. Quality soft serve products are best when
served above 20°F and 45%-60% overrun.

There have been few significant design changes to soft-serve freezers since
they were first introduced. Advances in technology have enabled manufac-
turers to make the dispensers smaller, but they still function essentially the
same way. A cold liquid mix is introduced from a remote storage vessel.
The mix is fed into a refrigerated cylinder and frozen. Revolving blades beat
in air, while scraping a thin layer of product from the cylinder wall. The introduction of air into the mix is es-
sential to developing the light and smooth product consistency, this also aids in product firmness. Soft-
serve freezers are designed specifically to produce either hard frozen soft-serve desserts or direct draw
milk shakes. The different consistencies of finished products are the result of the temperature at which the
products are frozen. Soft serve milk shakes and other soft serve beverage products are frozen to a temper-
ature of 20-28° F. Other soft-serve desserts, such as cakes and bars, are frozen to approximately 0°F.

Costing Soft Serve Mix

Product costs must be determined by weight. Volume of liquid mix put into the soft-serve dispenser results
in a higher volume of frozen product from the machine, because air is incorporated into the product in the
form of overrun. As a result the finished cost in ounces, times the mix cost in ounces, is the ice cream
product cost. Determine the weight of mix per gallon, converted to ounces, divided into the mix cost per
gallon, equals the mix cost per ounce.

Product costs must be determined by weight. Volume of liquid mix put into the soft-serve dispenser results
in a higher volume of frozen product from the machine, because air is incorporated into the product in the
form of overrun. In determining cost we must know the weight of mix per gallon. This figure, converted to
ounces is divided into the mix cost per gallon and equals the fluid cost/oz.

Example:
• 40lbs/case ÷ 5gal/case = 8lbs/gal
• 8 lbs/gal x 16oz (in a pound) = 128 oz/gal
• Cost of the mix $45 ÷ 5 gallons = $9.00/gal
• $9.00 (cost/gal) ÷ 128 (oz/gal) = $.07 cost/oz

10

Commonly asked questions

Where can I purchase my equipment?
At Kemps we manufacture ice cream and leave the equipment up to the refrigeration experts. We highly
recommend finding the equipment that serves both your needs and your budget. While we do not make or
sell equipment we do have contacts with distributors in that business. You can check online for the nearest
restaurant supply companies, broadliner sales forces, web sites, etc… Some companies we have recom-
mended in the Midwest are “Don Stevens, Inc”, in Minneapolis and along with Alamo Refrigeration availa-
ble on the web.

My ice cream is too hard?
Chances are that your temperature has not been regulated. If it is a new cabinet, it is typical that the man-
ufacturer shipped the unit turned to it its coldest temperature. Please remember that the temperature dial
should have a designated person to be in control of the dial. Many times multiple people in a store may
have changed the dial setting and it can take many days to get it regulated. If the temperature dial is at its
coldest or warmest setting and the temperature is still not correct… call for service because the cabinet
thermostat is not working.

My ice cabinet thermometer has a reading of 0°F but my ice cream is still soft?
It is imperative that the ice cream itself is tested versus the cabinet. Use a probe thermometer and insert it
into a tub of ice cream. Ideal temperature is between 0°F and 5°F. There are times when altitude and/or
humidity play a factor in the temperature of the ice cream and then it will need to be colder.

Some of the ice creams in the cabinet are hard and some are soft?
This is a very typical question. Traditionally, the coldest spot in the cabinet is in the upper left corner. At
times there are flavors that have a little higher melting point than others. Some soft flavor culprits are Mint
Chip and French Silk. Ask the customers to move the ice cream around into the cabinet to find the best
consistency/temperature for the flavor.

My ice cream has ice crystals in it?
Ice cream forms ice crystals most commonly when it has been warmed and then cooled again. Please re-
member the 3 things that break down ice cream are: air, temperature, and light. Survey where the cabinet
is in the restaurant in relation to windows, ovens, etc…

My ice cream scoops and spades have calcium deposits on them. What should I do?
Scoops and spades develop calcium deposits on them in left in hard water for periods of time. Dishwash-
ers can also create calcium deposits. This may be remedied by using a green Scotchgard™ pad and
household vinegar, or washing by hand.

11

Glossary

Ice Cream A practical definition: Ice cream is a frozen foam dairy product
comprised of dairy ingredients, sweeteners, stabilizers, and emulsifiers.

Variegate Typically a swirl of fruit or softer ingredients that can be combined into the ice
cream during production or serving.

Inclusion Any element/ingredient that is added to ice cream, such as candy pieces, fuits,
nuts, etc….

Allergen Usually harmless substance capable of triggering a response that starts in the im-
Dairy ingredients mune system and results in an allergic reaction. Typical allergens found in ice
cream can be milk, nuts, soy, or wheat.
Sweeteners
These will include Cream, milk, nonfat milk, buttermilk, whey, condensed skim.
These are listed at or near the beginning of the ingredient statement and are re-
sponsible for the dairy flavors and richness associated with ice cream.

This portion of the ice cream mix will be comprised of sugar (sucrose), fructose,
high fructose corn syrup, and/or corn syrup. Most often, more than one of these
sweeteners are used in the manufacture of ice cream. Ice cream mixes will typical-
ly contain a total sweetness level of 15-20% by weight of the mix. Sweeteners im-
part the desired sweetness levels to the ice cream, as well as helping to produce a
product that freezes well in production.

Stabilizers Stabilizers are functional ingredients. Very simply, stabilizers act as sponges. Used
at very low levels (generally less than 0.5%), stabilizers work to control the migra-
tion of free water during defrost cycles in retail and residential freezers. Stabilizers
prevents the "icicles" from forming in packages after they have been opened, and
also work to prevent a feeling of "coarseness" or " sandiness" that can develop in
ice cream after extended periods of time in retail and/or residential freezers. Locat-
ed near the end of ingredient statements, stabilizers will have names such as: lo-
cust bean gum, guar gum, carrageenan, methyl cellulose, cellulose gel.

Emulsifiers Emulsifiers maintain the oil-in-water emulsion that occurs during processing of an
ice cream mix. Very simply, emulsifiers are mediators between oil and water, two
substances that are chemically incompatible, and will separate if left untreated.
Emulsifiers are molecules that are water loving (hydrophilic) at one end of the mol-
ecule and fat-loving (lipophilic) at the other. The presence of emulsifiers in the ice
cream mix will prevent the recently homogenized fat globules (very small) from ag-
glomerating and forming larger fat globules that do not make as good of an ice
cream. Mono and diglycerides are most often used for emulsification, but other 12
sources include egg yolks, polysorbate 80, sodium carbonate.

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1270 Energy Lane
St. Paul, MN 55108 WWW.KEMPS.COM

1-800-322-9566