Making of ice cream in factory

Different types of ice cream making machines in factories

A batch freezer is a simple ice cream machine that works well when making small batches. It cools down the mix while churning to make ice cream. The ice cream maker can be a direct expansion or be kept cold with salt-ice. A direct expansion freezer uses a refrigerant in the mixing can to make ice cream, while a salt-ice freezer uses a brine solution to cool the mixing can. This type of ice cream making machine is best for small ice cream shops.

An ice cream machine with a heat exchanger and continuous freezer is more advanced. It has a heat exchanger that cools the mix before freezing, and it also churns and freezes the mix as it moves through. The ice cream is then constantly pumped out. This equipment works well for large-capacity ice cream production. Ice cream factories mostly use it because it can quickly make ice cream of the same texture and temperature.

Whipping air into ice cream is important to give it body and smoothness. An aerator adds the right amount of air before the ice cream is frozen. The amount of air in ice cream is called overrun. Overrun makes ice cream lighter and helps it stay fresh for a longer time. Using an aerator keeps the overrun steady.

The pasteurizer cools the ice cream mix to a specific temperature after it has been heated. This mix is then stored until the ice cream is ready. Cooling the mix prevents harmful bacteria from growing. Ice cream made from unpasteurized mix can make people sick because the bad bacteria can cause stomach problems.

Ice cream making machines in factories often have a hardening tunnel to freeze the ice cream quickly after it has been made. In the hardening tunnel, the ice cream is put on a conveyor belt that moves through a very cold freezer. Quickly freezing the ice cream keeps the taste and stops ice crystals from forming.

Function and feature of the ice cream machine in a factory

Ice cream makers perform various functions, from stirring and mixing the ice cream base to adequately freezing and serving it. The following are the critical features of factory ice cream machines;

• Refrigeration system: The refrigeration system is an ice cream machine's primary and most crucial feature. The refrigeration system rapidly freezes the ice cream mixture, creating tiny ice crystals essential for creating a smooth and creamy texture.
• Compressor: Most commercial ice cream makers feature a powerful compressor that can freeze the mixture quickly and maintain the desired low temperature. Ice cream makers with a compressor can freeze the mixture before serving it, producing fresh and creamy ice cream.
• Insulated mixing chamber: The mixing chambers are insulated to maintain low temperatures and prevent heat transfer from the surroundings. It helps preserve the quality and texture of the ice cream.
• Agitation system: Ice cream machines have a well-designed agitation system that stirs and mixes the ice cream base to incorporate air and create a smooth and even texture. The agitation system also helps to freeze the mixture quickly, forming tiny ice crystals that give the ice cream its creamy consistency.
• Pasteurization unit: Some ice cream machines have a pasteurization feature that heats the ice cream mixture to eliminate harmful bacteria and extend the ice cream's shelf life. The pasteurization unit also helps to develop the flavors and improve the texture of the ice cream.
• Control panel: The control panel allows users to adjust various settings, such as temperature, mixing time, and pasteurization temperature. The control panels also monitor and control the machine's operation, ensuring it works properly and produces ice cream of consistent quality.
• Flavor and ingredient dispensing system: This system consists dispensers for different flavors and ingredients, such as chocolate chips, fruit pieces, nuts, and other mix-ins. These dispensers evenly and automatically dispense various flavors and ingredients to create different ice cream varieties and ensure consistent portioning of mix-ins.
• Safety features: Ice cream-making machines have various safety features, such as emergency stop buttons, door interlocks, and protective guards, to ensure safe operation and prevent accidents.

Scenarios

Ice cream is a popular dessert that people enjoy eating worldwide. However, because of its high demand, ice cream is in great supply, and consumers can buy it in different quantities. An ice cream production machine comes in handy when making ice cream on a large scale.

Ice cream can also be made at home. Nonetheless, ice cream factory machines are more convenient for mass production. There are different ways to use ice cream-making machines. The batch machines are useful in making ice cream in a single batch. To make soft-serve ice cream, direct-reading machines that provide instant output are more suitable. These kinds of machines are also efficient when making ice cream served in food chains, restaurants, or vending trucks. Pump machines can be used to store ice cream in cold-temperature tanks. They also have a refrigeration system to maintain the low temperature.

The kind of ice cream machine to be used is determined by the amount of ice cream to be produced, the power source, and the ice cream's texture. Using the right ice cream machine will help achieve the desired production output.

How to Choose Making Of Ice Cream In A Factory

When opting for a method of ice cream production, a buyer or manufacturer needs to consider various factors that surround cost, durability, and functionality. The following are some of the considerations to make;

• Scale of production: Before settling on any production equipment, buyers should analyze and determine the amount of ice cream they want to produce daily. For large-scale production, buyers should opt for equipment with high capacity and efficiency. On the other hand, those in the small-scale production business can settle for single-serving machines or batch freezers.
• Production process: Different equipment caters to different production processes. From pasteurization to aging and mixing, buyers should settle for machines that handle all the processes efficiently. Ideally, a complete ice cream production line should include a pasteurizer, freezer, hardening, and filling machine.
• Capacity and size: The capacity and size of the machine should be carefully analyzed and matched with the available factory space. It should also be matched with the daily production requirements. Commonly, ice cream machine capacities are classified into three categories: small (less than 20L/hour), medium (20L/hour to 100L/hour), and large (more than 100L/hour).
• Energy efficiency: It is important to go for energy efficient machines. This is because, generally, the making of ice cream in a factory requires a lot of energy in the different production stages. Efficient machines reduce energy consumption and help save costs.
• Compliance with industry standards: Buyers should be keen to ensure that the machines they choose comply with the relevant industry standards and regulations. These regulations are often related to food safety, hygiene, and environmental protection. Ideally, the making of ice cream in a factory is subject to strict regulations to ensure consumer safety.
• Material and construction: The materials and construction of the machine should be durable and non-corrosive. Buyers should go for stainless steel construction, which is durable, non-corrosive, and easy to clean and maintain.

Ice cream factory Q & A

Q1: What type of packaging is used for ice cream in bulk?

A1: Ice cream is typically packaged in containers or tubs made of plastic or metal for bulk storage. These materials provide airtight seals that prevent freezer burn while protecting the product from contaminants. Additionally, they may feature insulation layers to maintain low temperatures during transportation and storage. Tubs come in various sizes, from a few liters up to several hundred liters, depending on the producer's needs.

Q2: How is the ice cream kept at low temperatures during transport?

A2: Special refrigerated trucks or containers are used to transport ice cream. These vehicles have built-in freezers that maintain constant low temperatures (-20°C to -25°C) required to keep ice cream solid. Before loading the ice cream, these trucks are pre-cooled to the proper temperature. Moreover, proper insulation in the vehicle prevents heat from entering, keeping the cold inside.

Q3: What safety rules are followed when making ice cream?

A3: There are several rules and guidelines to ensure ice cream is made safely. The FDA has regulations that cover things like the safe temperatures for pasteurizing milk and cream. Ice cream factories also need to have proper sanitary conditions to prevent contamination. These include cleaning machines and hands often, using food-safe materials, and keeping the production area clean. Additionally, ice cream must be made using specific quality ingredients.

Q4: How is quality checked during the ice cream-making process?

A4: Ice cream factories have quality control methods to make sure the final product is consistent and good. Measurements are taken to monitor things like temperature and mixing speed. These measurements help check that the production process is working correctly. Also, workers regularly check the ice cream's taste, texture, and appearance to ensure the quality is up to standard. They also examine the packaging to confirm it is sealed.