2019 Ice cream factory

Ice cream factory

Plant components/Machines

Components Power Manufacturer 2019

1. compressor / compressed air supply 0,68-3,21 m3/min Boge

2. cooling tower (ripening tanks) 16 kW Debusmann

3. cooling tower (pasteurizer) 16 kW Debusmann

4. water cooling (pasteurizer) 41 kW Technogel

5. water cooling (ripening tanks) 25 kW Technogel

6. sugar tank incl. sugar dosing Volume: 44 m3 Zeppelin

7. milk tank + pump house volume: 25 m3 Fabdec

8. 2x Mobile tank unit incl. dosing Volume 1 m3 / Big Bags can also be used

volume 1 m3 Automation- technik GmbH

9. HTST (pasteurization) incl. homogenizer and

2 mixing tanks

2 m3/h Technogel

10. powder mixer 1000 kg/h Technogel

11. 10x ripening tanks volume: 2.4 m3 Technogel

12. 2x Freezer for line filler (cup filler) 2x 0,4-1,6 m3/h Technogel

13. 1x Freezer for filling robot 0,4 - 1,6 m3/h Technogel

14. fruit feeder Technogel

15. pneumatic shaft pump Technogel

16. 2x inkjet printer Technogel

17. line filler Same capacity as the freezer

Can simultaneously fill up to 4 ice packs of sizes

1.25 l or 0.5 l with different flavors including

flavors included

Technogel thermal seal

18. filling robot for ice cream trays Same performance as the freezer (13) Technogel

19. conveyor belts 12,5 m/min Technogel

20. freezing tunnel and associated conveyors Not included in sales price Nippon Gases

21. CIP plant consisting of 5 tanks

1. Hot water

2. hot water

3. acid

4. lye

5. neutralization

- Cleaning of the whole plant

- Volume per tank: 2m3

22. steam generator steam capacity: 600 kg/h

Heating capacity: 328 kW Certus

23. product piping

24. control

Pos. 4 and 5: Water Chiller (pasteurizer)

Application:

It produces and maintains a certain quantity of chilled water (1° C) necessary to cool the liquid mix

for ice cream down to 4° C, which is contained in pasteurizers and/or in ageing vats.

Description and specifications:

At the top there is a tank of about 400 liter capacity, built entirely of stainless steel with:

 high-efficiency exchange plates in stainless steel immersed in water

At the bottom:

 refrigerating equipment for cooling water contained in tank

 air blower for the agitation of water in the tank

 centrifugal pump in stainless steel for water circulation from the tank to the users and return

 thermoregulator with display for the regulation and control of the various functions

Pos. 9: HTST ((pasteurization)) incl. Homogenizer and 2 mixing tanks

Application:

Continuous cycle plant for the pasteurization of a mixture for ice cream (using hot water in a “bain-

marie”), homogenization, pre-cooling and instantaneous cooling until 4° C.

The whole thermal cycle (20-55-75-85-65-35-4° C) occurs using the “HTST” technology (high

temperature in a short time) and automatic control of the pasteurization temperature: if it is not

reached, the machine automatically deviates the mixture at beginning of cycle and releases a sound

alarm. With the “HTST” technology, the thermal cycle is done saving 28% energy.

Operation:

 preheating and mixing of ingredients up to 55° C w ith gas boiler

 self-heating up to 75° C with heat recovery

 homogenization at 75° C (optimum for crushing the mixture molecules)

 pasteurization at 85° C and stop for 20 seconds at this temperature

 self-cooling at 65° C with heat recovery

 cooling to 35° C with Tower or w ell water

 final cooling at 4° C with chilled water

Services required for the machine:

 Steam at 3 Bar pression Kg/hour: 300

 Tower water at + 29° C Kcal/hour: 60000

 Chiller water at + 2° C Kcal/hour: 49000

 Compressed air 7 Bar, NL/minute: 10

Pos. 11: 10x Maturing tanks

Application:

Conservation, ageing and maintaining the mix for ice cream after pasteurization, at a temperature of

4° C w ith slow stirring.

Description and features:

 Reservoir of cylindrical form constructed entirely of stainless steel with:

 Lateral air space for the circulation of cold water at 2° C for cooling the mix

 Lid for inspection and introduction of ingredients complete with safety valve operating on

opening

 Low and High speed gear motor with dismountable stirrer with large blades

 Thermoregulator indicating temperature in display

 Throttle-type outlet tap DN 25

Services required for the machine:

Chilled water at + 2° C Kcal/hour: minimum 2000 maximum 3000

Pos. 12 and 13: Freezer

Application:

Continuous production of ice cream w ith variable volume increase from 30 to 100% with hardness

and temperature suitable for extruded ice cream (until -8° C) and/or for filling immersion moulds

with semi dense ice cream at -2° C.

Description and features:

The machine is equipped with “Touch screen” for a direct and immediate control of the machine

functions:

 Setting and checking the hourly output of ice cream

 Setting and checking the ice cream “ Overrun”

 Setting and checking the ice cream viscosity

 Set up and control of the temperature of the ice-cream in out-put

 Self-diagnosis w ith photographic display indication of the defective part and w ith

description of the cause

One may insert up to 20 recipes with production dates In the internal lower part, a double-pump

pumping group with alternative movement pistons sucks a mixture for ice cream (in liquid solution at

4° C stored in a ageing vat) from the first pump and sends it to the second pump that is larger than

the first one, which receives compressed air (quantity adjusted on the control panel), and sends

them together, air and mixture, inside the freezing chambers first in one and then in the other (with

high refrigerating efficiency). Here a mixer of hollow type with eccentric shaft in stainless steel and

provided with wiper blades, also in stainless steel, by rotating at high speed produces an ice cream of

great structure.

Advantages of the system:

 Possibility of obtaining ice cream with volume increase from 30% to over 100%

 The set volume increase of ice cream (Overrun) and the viscosity (hardness) are maintained

constant from beginning to end of production, even when changing the amount of ice cream

produced

Pos. 14: Fruit feeder

Application:

Inclusion of dried, syrup, candied fruit, cookies, candies, chocolate pieces and else with minimum

dimensions of 2 mm. and maximum dimensions of 10 mm. in the ice cream by continuous cycle. The

most widely used products are: walnuts, hazelnuts, dried raisins, cherries, chocolate pieces, melted

chocolate, nougats, broken biscuits, etc.

Description and features:

The machine has a tank of 30 liter capacity, equipped with stirrer, in which the ingredients to be put

in ice cream are poured. Below it, a continuous spiral screw feeder moved by inverter and controlled

by PLC, pours the amount of ingredients to be placed in ice-cream into the pump placed below.

 The machine is fitted as standard with two screw feeders: one is for low flow rate and one

for high flow rate

 The average amount of ingredients that can enter the machine is 10% of the ice cream

stream that passes through the machine

 The machine can receive streams of ice cream from 150 to 1500 liters/hour at a temperature

of –5° C / -8° C.

 For very low amounts of ingredients, the machine has a low -capacity programme that allow

s, by setting the minimum speed intermittently, to reduce almost to zero the amount of

ingredients to be placed in.

After the rotary/alternative piston pump has entered the ingredient in the ice cream, a vertical mixer

will evenly distribute the ingredient in ice cream before it leaves the machine.

 The three motors driving the screw feeder, the product introducing pump and the final mixer

are all moved by inverter, and their speed can be adjusted individually by PLC

 Self-diagnosis: Inscriptions warning of any possible anomalies occurred in the three motors

are shown on PLC

 A specific C.I.P. programme is available on PLC, and it can be included at the time of washing

the machine (the tank is excluded from the C.I.P. washing)

 All the main pieces of the machine can be disassembled for cleaning and sanitation

 All parts in contact with the ice-cream, are made from stainless steel or from first quality

sanitary materials

Pos. 15: Pneumatic ripple pump

Application:

Pumping of sweetened syrups (black cherry, chocolate, kiwi, etc.) normally used to ripple ice cream

continuously.

Description and features:

The machine is equipped with a stainless steel tanks of 25 liter capacity that contains the syrup to be

injected in ice cream. The tank is neither heated nor cooled. A pneumatic pump w ith alternative

motion immersed in the tank, sucks and pushes the syrup to the user w ith high pressure. The speed

and, therefore, the syrup flow rate are determined by a manual pneumatic regulator, which,

increases or reduces the compressed air in the pump, increases or reduces the quantity of syrup to

the user.

The machine can work coupled with a Freezer (see figure)

Pos. 17: Linefiller

Description and Features:

A series of trays suitably shaped for containing tubs, coupled to two chains in stainless steel, move

intermittently driven by a "brushless" motor..

Along the way, the various stations required by the customer are installed, such as the loading of

tubs / cups / cones, various decorations, pre-cut lid dispenser and closing, date coder etc. The

sequence of working steps is controlled by a computerized system, suitably programmed, which

activates the necessary operations. All movements and dosages are coordinated and controlled by

PLC with touch-screen interface from the general control panel. The PLC allows changing the working

parameters of the various stations while the machine is in operation with ability to customize and

store various parameters.

The machine consists of a frame made of stainless steel AISI 304 and safety guards made according

to CE standards. The electric panel is placed vertically in the outlet area of the products, and is made

according to the standard IP67.

The machine is equipped with wheels and locking pin in stainless steel. Particular importance has

been given to the easy of the washing and sanitizing operation, since the machine is open, and

inspection is possible from both sides.

Products and dosing capacity:

 2 sizes of cups: 1250 ml and 500 ml and n.1 size of tube (1 liter)

 Max number of strokes per minute per row: 25/30 (20 with thermosealing)

Stations of the machine:

 Cup placement dispenser

 Doser ice cream station 1 flavor with variegation:

 Crunch doser

 Topping

 Thermosealing with precut lids

 Lid placement dispenser

 Lid on press

Pos. 18: Filling robot for ice cream trays

The ROBOTIC DOSER is composed by:

1. loading belt for containers, made in anti-slipping and food grade material, with continuous

motion, controlled by a photocell that activates the overflow ;

2. 2belt for positioning of the containers in the filling area;

3. side filling area to recover the ice cream during the starting phase or in case of emergency

stop;

4. Dosing station made w ith exclusive TRACKING technology (the container is in movement

while filled, so as to minimize the cycle time and therefore increase the productivity of the

system;

5. Ice cream doser, connected to a pneumatic valve, w here the ice cream flow s directly from

the continuous freezer; the doser is installed on the terminal part of the robot, and it fills the

container according to the needs of the user;

6. SAFE DOSING system; the TRACKING technology allow s the system to have the complete

control of the filling and decoration; in fact, through the use of an encoder, the TECHNOGEL

ROBOTIC FILLER is able to automatically stop the container and finish the decoration.

7. Ejection of the finished product through belt;

8. Protection according to CE safety norms;

9. No. 3 program for filling family packs (trajectories)

Main characteristics:

 “Clean room” version.

 2 belts;

 Photocell to activate the dosing according to the product;

 1-2 flavors dosing;

 Ripple connection;

 Automatic dispenser included

The machine has been designed to be compact, clean and easy to use, fully compliant with food

environments as the materials used are all certified food safe.

The following functions are available on the DOSING ROBOT

 automatic de nest of containers;

 size change for de-nest;

 Different types of filling / decoration are available (up to 3).

Pos. 19: Automatic Belts

Four different segments with the following functions:

a) From Robot DR 7 to existing azote hardening tunnel –. Automatic loading of the product. Belt

A

b) From Linear Filling machine to existing azote hardening tunnel. Automatic loading of the

product. Belt B Conveyor belt which takes the products from belt A and belt B. Belt C

c) Ink jet printer belt. Belt D

Speed: 12,5 m/min

Pos. 10: Powder mixer

Application:

Device for mixing water or liquid milk with dry powder substances, such as sugar, milk powder and

other.

Description and features:

The machine consists of a high-speed motor located in the lower part, which drives a centrifugal

pump that sucks, on the one hand, the liquid contained in the reservoir, on the other, as a result of

the “Venturi” effect, the dry powered matter and sends them together to the reservoir in the upper

part. The hopper, w here powders are poured in, has a butterfly valve to regulate the passage

between the hopper and the centrifugal pump.

The turbulence movement caused by the pump, has the effect of uniformly mixing liquids with

powders.

The practical operation is to keep the liquid in the reservoir constantly circulating until all solids

added into the hopper are mixed up with the liquid.

Once the liquid in the first reservoir has been mixed, by acting on the special taps provided you can

begin the mixing of the

Find more here - https://www.ucymachines.com/