Cow to Cone – Brymor Dairy
Guernsey Cows

The Milking

Once upon a time to get the milk, everything had to be done by hand but now our girls are milked by Phil Carlisle and his team in the modern milking parlour, they often enjoying a one to one conversation whilst being milked! The girls are tucked up warm at night in one of the barns at night then at 5.30am every morning they head down to the milking parlour to eat their breakfast while they are being milked. Each of one of our herd wears a special collar with a micro chip and unique number to identify who’s who in the herd. We can also record how much milk each of the girls produce and how much feed we need to giver them to keep them fit and healthy. Cows love a routine and they are always eager to see Farmer Phil. it has been scientifically proven happy cows produce more milk, and our milk yield has recently been steadily increasing so our girls must be happy!

Our girls spend the whole of the day happily grazing on lush grass until Phil gives them a whistle at 3.00pm to head back in to the parlour for their afternoon tea and second milking session.The milk goes straight in to our dairy, guaranteeing that our milk is super fresh, it’s is stored in a large 5000 litre tank and kept chilled at just the right temperature. We then skim it to make Clotted and Double Cream or we use the whole milk as the main ingredient in our ice cream mix. All the recipes for our 25 plus flavours are all kept as a closely guarded secret.


The Mixing

This is undertaken by our very important master mixer who knows our recipes off by heart and is sworn to secrecy! With each mix, he adds the precise amount of each ingredient to create our delicious ice cream. First, he adds our fresh whole milk and double cream, then pure cane sugar, skimmed milk powder and stabilisers which help give the ice cream more texture. The mix is then heated to kill any harmful bacteria in the raw milk, known as pasteurisation.

Next, to make sure that the fats in the mixture are as small as possible, the mix is homogenised which ensures the ice cream has a smooth finished texture. The mix is then passed through a plate cooler which rapidly chills it, and then it is pumped into an aging vat overnight where it is continuously stirred by a paddle and kept at a very low temperature.

The agitation of the paddle overnight helps to chill the mix and it enables the milk to become smoother and richer when frozen. Any background flavourings such as caramel, mint or vanilla are then added to the mix before the freezing process.

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How do we get the Milk?

The Freezing

Once the mix is frozen it’s still not quite ice cream just yet. We have to whip the mix gently, adding just the right of air into the mix that gives ice cream its distinctive texture and creamy taste. If we didn’t add air the ice cream would be rock solid, but too much reduces the intensity of the flavour. Cheap ice creams have a much higher percentage of air in their ice cream, here at Brymor we keep the air to a low optimal level making for deeper, more intense flavour. Just before the ice cream leaves the pump we add only the finest, wholesome ingredients through a fruit feeder ensuring they are evenly distributed through the ice cream.

 

It’s then packaged and put into a blast freezer at -30° which kills any remaining bacteria. Blast freezing is also essential to making the best tasting ice cream because it stops the water from congealing and forming crystals which will ruin the creaminess and texture of ice cream. Our ice cream is then held at -18° in our huge freezer. When it is ready to be delivered it is transported in temperature controlled vans so every order reaches all our customers in their farm shops, delicatessens and cafes in perfect condition.

 

After all the magic, it’s time for the important part – tasting! We taste a sample from every single batch before it leaves our production unit. We recommend if you are enjoying our ice at home you take it out of your freezer for ten minutes before you serve it. All you need to do is enjoy it!