WCB Ice Cream. Introduces the. CREAM Freezer

Transcription

1 WCB Ice Cream Introduces the CREAM Freezer

2 It s NOT About Making the Coldest Ice Cream! It s About Making Better Ice Cream! The CREAM Freezer Produces Ice Cream With: Small Ice Crystal Size Small Air Cell Size Creamier Mouth Feel Premium Tasting LOW FAT Products Better Eating Quality for ALL Products

3 Preliminary: Low-Draw Temperature Ice Cream The term Low-Draw Temperature Ice Cream refers to the process of producing ice cream or related products (low-fats, sherbets, frozen yogurt, etc.) exiting the freezer at temperatures less than the traditional -5.6 o C / 22 o F. Low-Draw Temperature Ice Cream is not new to Ice Cream Industry. For many years freezer manufacturers have had freezers capable of producing low-draw temperatures, but only recently have ice cream manufacturers been able to find ways to produce products that can be handled with conventional equipment. Product reformulation has helped the production of usable products.

4 The Objective: To Make Better Ice Cream (At the same or less cost) Not the coldest ice cream Low Draw Temperature Ice Cream Gives Us Only Part of the Solution: Creamier mouth feel obtained by additional working of the fat Small ice crystal size Improved melt down time Better eating quality not icy But does it last?

5 The Objective: (continued) To Make Better Ice Cream We also would like to have: Smallest air cell size More uniform distribution of ice crystals, air cells and fat globules - homogeneous Not require any special equipment to handle the finished product Do it without massive investment

6 The Objective: To Make Better Ice Cream The Wish List: What If I Could Also Have: Better package weight control Save energy Do it in the same floor space Survive the distribution chain! (Better resistance to heat shock) BETTER EATING QUALITY FOR THE CUSTOMER

7 The WCB Ice Cream Solution WCB Ice Cream s CREAM system produces the benefits of low-draw temperature technology while utilizing a more practical approach. The acronym CREAM stands for the:»continuous»re-circulation with»emulsification of»air and»mix Patent Pending

8 The WCB Ice Cream Solution The objective of ice cream made with an ice cream freezer plus a secondary cooling unit is to produce finished ice cream with small ice crystal size and a creamier mouth feel, giving better eating quality and storage stability. Similar results are obtained with the CREAM System without the need of a secondary unit. Additional benefits are realized with the CREAM System. Patent Pending

9 CREAM Freezer System The CREAM Freezer utilizes these features: Continuous Product Re-Circulation Pre-Aeration Optimum Dasher Speed Selection CREAM Dasher Assembly Highly Refined Freezer Control

10 Principals of Operation

11 Principals of Operation Continuous Product Re-circulation: WCB Ice Cream s unique continuous re-circulation feature allows a percentage the frozen product to be re-circulated to the freezer inlet seeding the freezing process with small ice crystals. The in-coming mix is pre-cooled by combining the colder partially frozen re-circulated product with the warmer in-coming mix in the pre-aerator. The amount of mix temperature reduction is contingent on the following: Temperature of re-circulated product Percentage of water frozen in the product re-circulated Percentage of product re-circulated Varying the above parameters allows the producer to vary the properties of the finished ice cream.

12 Principals of Operation (continued) Pre-aeration: The pre-aeration mixer provides the following benefits: The mixer shears overrun air into the mix creating a fine emulsion prior to the freezing cylinder, creating a very consistent product with improved air cell distribution. This fine emulsion contains very small air cells that promote formation of small ice crystals. The mixer mechanically works the fat producing a very creamy product texture. Pre-aeration greatly improves the body of no fat and low fat products.

13 Principals of Operation (continued) Pre-aeration VERY IMPORTANT POINT: Pre-aeration and working of the product prior to the freezing cylinder transfers less heat energy into the product than doing it in the freezing cylinder or in an auxiliary unit after freezer cylinder where the product is in a more viscous state. Therefore, less energy is required for the process.

14 Ice Cream Freezer Operation (continued) Exploded view of the pre-aerator

15 Principals of Operation Optimum Dasher Speed Selection Over 90% of the dasher motor power is transformed in to heat energy and must be removed by the freezer s refrigeration system. This heat energy adds up to 30% to the product heat load. Decreasing the speed of the dasher to the most efficient speed lessens the heat load and this allows draw temperatures less than the traditional to be reached or increased capacities at the traditional draw temperature. The CREAM freezer utilizes a variable frequency inverter to optimize the dasher speed thus maximizing the freezing efficiency.

16 Principals of Operation CREAM Dasher Assembly The CREAM freezer utilizes a modified dasher assembly to assure proper scraping of the frozen product from the cylinder wall and adequate working of the product during the dynamic freezing process. The modified dasher averts any coring action of warm mix through the center of the dasher.

17 Principals of Operation (continued) The CREAM Dasher

18 Principals of Operation Highly Refined Freezer Control The freezer controls provide for storage of CREAM parameters for each of your products as the optimum settings can be expected to vary with different products. The amount of product re-circulation is selected from the touch screen. The selected flow is achieved by means of a variable frequency inverter regulating the speed of the re-circulation pump. True overrun air proportioning is accomplished utilizing an air mass controller to ratio the air to the actual mix flow rate determined by the mix flow meter, all controlled through the PLC The pre-aerator speed is selected from the touch screen operator interface and maintained with a variable frequency inverter.

19 Principals of Operation Highly Refined Freezer Control (continued) The most efficient dasher speed is selected from the touch screen and a variable frequency inverter maintains that speed. The product viscosity is selected and control is provided by the PLC using a watt transducer to measure the true power of the dasher motor. A motorized refrigeration back-pressure valve regulates the refrigeration, eliminating the nominal 3 to 5 psi pressure drop of a traditional gas operated back-pressure valve. This provides additional energy savings with the refrigeration system by allowing the same refrigerating effect with a warmer suction. The cylinder pressure is selected and then controlled by the PLC using a sanitary pressure transducer to measure the cylinder pressure and a variable frequency inverter to regulate the speed of the product pump.

20 Principals of Operation (continued) The CREAM Freezer has the same footprint as the standard WS Freezer!

21 CREAM Freezer Guidelines CREAM product is more flowable than comparable low draw temperature product, thus allowing incorporation of inclusions and variegates. The draw temperature can only be lowered to the point that the product can still be packaged efficiently. CREAM product gives more latitude. The optimum draw temperature may be found to be somewhere between the traditional 5 0 C / 22 0 F and C / 10 0 F. Lowering the draw temperature below the traditional will reduce the ice crystal size and increase the percentage of water frozen at the ice cream freezer (see the graph on the following page). Product re-formulation should be considered to fully realize all of the benefits.

22 Product Draw Temperature Verses % of Water Frozen 10 0 C / 14 0 F 70% C / 18 0 F 65% C / 22 0 F 50% % Water Frozen Temperature (C) Ice Cream Viscosity at C = 1x Ice Cream Viscosity at C = 5x Ice Cream Viscosity at 10 0 C = 14x

23 Benefits The CREAM System produces ice cream or related products with: Very small ice crystal size Creamier mouth feel due to the additional working of the fat These characteristics are produced without requiring low draw temperature or a secondary unit. In addition the CREAM System provides Small air cell size and improved air cell distribution Improved melt down time Improved storage stability and resistance to heat shock Enhanced texture and consistency BETTER EATING QUALITY The CREAM System provides large energy savings and floor space savings compared to alternate low draw temperature processes.

24 Benefits (continued) The CREAM System can provide improved texture of lower fat content product to have the same mouth-feel as products with a higher fat content. Possibilities include: Lower fat / calorie products with traditional taste Standard ice cream with premium ice cream characteristics The producer gets a very consistent product resulting in excellent package weight control. The producer can reduce the load on the hardening tunnel. The CREAM System provides large energy savings and floor space savings compared to alternate low draw temperature processes.

25 Additional Solutions for Viscous Ice Cream An Ingredient Feeder that does not interrupt the ice cream flow Filling technology for viscous ice cream

26 The IF-1230P Ingredient Feeder Design

27 The IF-1230P Ingredient Feeder Design

28 RUF Filler Proven for use with Low Temp Ice Cream Extrusion and/or Gelderland filling Easy change-over for sizes or filling system Small Footprint

29 Applications: Bulk and cup filling Ice cream with any size inclusions Filling low temperature / stiff ice cream Multi-flavor filling Complex patterns are possible Best filling accuracy

30 Bulk product down to pint size Ice cream with high or low viscosity 1, 2 or 3 Flavor filling Ice cream with big inclusions, up to 25 mm ( 1 ) Quick start up - Little waste of ice cream

31 It s NOT About Making the Coldest Ice Cream! It s About Making Better Ice Cream! The CREAM Freezer Produces Ice Cream With: Small Ice Crystal Size Small Air Cell Size Creamier Mouth Feel Premium Tasting LOW FAT Products Better Eating Quality for ALL Products

32 The Bottom Line The CREAM System does not require the large capital investment associated with secondary cooling units. The CREAM System does not require large floor space. The footprint is the same as a standard WS freezer. The CREAM System does provide the capability to produce product with better eating quality, improved melt down time and better storage stability. What we all want: Better Ice Cream Delivered To Your Customer!

33 Our mission is to provide our Customers the latest technology in the most cost effective method.