Tetra Pak Rotary Moulder 35 A2 Moulded stick novelty freezer Here shown with Tetra Pak Volumetric Bottom Filler Highlights Operating principle Increased efficiency with servo controlled mould table index, extractor functions and positive lay-off to wrapping Gentle product handling and best hygiene with direct lay-off to multi lane wrapping Fast product / size change over Best ice cream texture and incorporation of inclusions with optional viscous bottom filling with Tetra Pak Volumetric Bottom Filler The production of ice cream stick novelties is carried out in six main stages: Application Automatic, continuous production of ice cream, sherbet, or fruit juice stick novelties. 1. Filling of ice cream into the moulds. 2. Insertion of wooden sticks into the ice cream. 3. Freezing of the stick novelties in a cold brine bath at 40 C ( 40 F). 4. Defrosting of a thin outer layer of the stick novelties in a warm brine bath at +15-25 C (+60-77 F). 5. Extraction of the frozen stick novelties from the moulds. 6. Lay-off for packing. Between extraction and lay-off, the stick novelties may be coated with chocolate. Products dipped in chocolate may also subsequently be coated with dry ingredients.
Tetra Pak Rotary Moulder 35 A2 Moulded stick novelty freezer Operating principle The number of freezing pockets per radial row depends upon the width of the ice cream stick novelty. For example: Capacity The capacity for typical products (see tables) will normally be in the range of 21 000 to 42 000 ice cream stick novelties per hour. Capacities for water ice are approximately 20 % lower than for ice cream. Actual capacity depends upon a number of factors, including: Example Max. width of product Pockets per radial row 71 mm (2.80 ) 12 59.5 mm (2.34 ) 14 * 51.5 mm (2.03 ) 16 * 39.5 mm (1.56 ) 20 Number of radial rows. 32 mm (1.26 ) 24 Number of products per radial row. 26,5 mm ((1.05 ) 28 Product thickness. The number of radial rows depends on the thickness of the ice cream stick novelty. For example: Recipe (e.g. sugar content and total solids content). Overrun. Example Viscosity of ice cream mix. Max. thickness of product Brine temperature. Number of radial rows * Up to 21.5 mm (0.85 ) 135 Ice cream filling temperature. * 21.5-24 mm ( 0.85-0.94 ) 126 Number and types of filling operations. 24-27 mm (0.94-1.06 ) 117 27-30 mm (1.06-1.18 ) 108 30-33 mm (1.18-1.30 ) 99 Capacity of the packing line. There are 11 strokes between chocolate dip and lay-down. This gives a drying time of 22 sec. at maximum strokes per min. Example * Typical products. Product width 49 mm (1.93 ) Standard design Product thickness 19 mm (0.75 ) Mould table Number of radial rows 135 Number of pockets per row 16 Overrun of ice cream 60% Evaporating temperature 45 C ( 49 F) Brine temperature 40 C ( 40 F) Ice cream filling temperature Capacity, approx. 3 C (+27 F) 25 900 per hour The capacity is based on a mix recipe using good quality ingredients as follows: Fat 10.0 % Skimmed milk powder, fat free 10.5 % Sugar (sucrose) 12.0 % Glucose syrup 5.0 % Auxiliary ingredients 0.5 % Total solids 38.0 % Water 62.0 % Total 100 % The moulds, in which the stick novelties are shaped and frozen, are welded into an annular, rotary table situated on top of the brine tank. The mould table is made of stainless steel. The number of pockets included in the standard mould table with 16 pockets per radial row is 16 x 126 = 2016 pockets. With 126 radial rows the max. thickness of the products is 24 mm. Other mould tables with different row and pocket configurations can be supplied (see Optional equipment). The mould table of a Tetra Pak Rotary Moulder 35 A2 can handle ice cream stick novelties up to 144mm (5.67 ) long. The stick inserted in the ice cream/water ice stick novelty must protrude at least 30 mm (1.18 ) above the mould table. Brine tank The double-walled annular tank is welded and insulated. It is made from stainless steel. The only exceptions are the inside bottom and the evaporator which are made from milled steel.
Two rails are placed on the outside of the brine tank for mounting the stick dispenser, the cleaning equipment, the filling equipment, etc. The brine tank is divided into a freezing zone with cold brine and a defrosting zone with warm brine. Cooling system The warm brine temperature is electronically controlled and is also displayed on the control panel. PLC and servo controllers are mounted in the control panel for easy and trouble-free installation. An audio warning alarm is also included. The touch screen also provides operation and diagnostic information. The primary cooling system consists of a semi welded titanium plate heat exchanger. Communication with a central computer and a larger computer instead of the standard PLC can be supplied if required (see Optional equipment). Ammonia/ NH3 is used as refrigerant, optional CO2 or R404A. Filling equipment The secondary cooling system is a cold brine bath, and the cold brine is circulated by a pump. The cold brine distribution trough is made of stainless steel with special nozzle plates to control the vertical brine distribution around the mould pockets. Low energy, frequency driven centrifugal brine pumps with flow capacity controlled from the recipe set-up in the PLC. Defrosting system The warm brine is heated either by steam or optional by electrical or hot water or similar. The choice must be made when ordering. The brine is sprayed vertical onto the underside of the moulds through a nozzle system. The defrosting system is equipped with a separate centrifugal pump. A thermostat prevents operation of the extractor if the warm brine temperature is too low. The warm brine temperature must be kept below 25 C (77 F) at all times to protect the mould table from too much thermal stress, which can reduce the life time of the mould table. Main drive All main functions are servo controlled through the PLC and HMI. The auxiliary functions and other functions with limited power demands are controlled and actuated pneumatically. The speed of the Tetra Pak Rotary Moulder 35 A2 moulded stick novelty freezer varies between 10 and 30 strokes per minute. Electric equipment The equipment is housed in a separate epoxy-coated power cabinet and consists of a main circuit breaker, circuit breakers, motor starters, variable frequency inverters including protection, control relays for heating elements, transformers for control voltage and a PLC and touch screen HMI (Operator panel). Control panel Operations are controlled from one control panel mounted on the machine. All functions are PLC controlled providing a high degree of automation. The control panel includes a touch screen operator panel and displays the ammonia evaporating temperature, temperatures for the cold brine and warm brine. The standard ice cream filler is designed as a drum type volumetric filler for top filling of ice cream and consists of a column and a filling head, on which the interchangeable filling equipment is mounted. Tetra Pak Automatic Stick multi A2 automatically loaded stick inserter It separates and inserts sticks automatically into the ice cream stick novelties, and the loading of sticks from bulks is also automatic. Included is a separate main drive, PLC control, main magazine for bulk cartons, servo stick feeder and a reserve stick magazine. Extractor and lay-off device The device consists of an in-line chain conveyor with 50 extractor arms carrying extractor tongs for wooden sticks. The tongs are made of hard metal/stainless steel. The products are transferred from the extracting arms by a servo controlled lay-off system direct to the top of the wrap lanes of the multi-lane wrapper. Individual exit function is included for pre-release, just before the lay-off position. Chocolate coating equipment This equipment is mounted beneath the extracting device and comprises a dipping cup and a drip tray with drip scraper. The height of the dipping is adjusted by the servo controlled down motion, according to the level of»dip«required. An external chocolate tank and a circulation pump are required, e.g. a Tetra Pak Pump Station (see Optional equipment). Washing and sterilizing apparatus For cleaning-in-place and sterilizing-in-place (CIP/SIP) of the mould table, a washing apparatus is supplied for mounting on the supporting rails on the brine tank. The apparatus requires connection to water and steam and proper cleaning detergents. Platforms Platforms of stainless steel covering the operation area are supplied.
Tetra Pak Rotary Moulder 35 A2 Moulded stick novelty freezer Standard equipment included in basic machine Main drives (servo controlled) Brine tank with cold brine circulation pump Defrosting system with warm brine circulation pump Control panel Plc control and touch screen operator panel Extractor in 16 rows Chocolate coating equipment Platforms of stainless steel Optional equipment 01 Filling equipment for one-coloured ice cream. 03 Moving product inlet system for uniform ice cream distribution in filler hopper. 04 Servo bottom filling machine for one-coloured ice cream. 13 Pencil filler with equipment for two strings of ripple mass per bar. 14 Filling equipment for slushed water ice on standard ice cream filler, including moving product inlets and cut-off nozzles. 15 Dry coating equipment for coating the bars with granulated dry ingredients such as nuts, candy, etc. 16 Tetra Pak Combi Top Filler for ice cream with or without inclusions. The dosing volume is adjustable on-the-fly 17 Tetra Pak Volumetric Bottom Filler for viscous bottom filling of products with inclusions. 18 Tetra Pak Automatic Stick multi A2 Stick dispenser with automatic loading. The stick dispenser is an independent unit and is designed for mounting on the bar freezer. It dispenses sticks automatically and place them vertically into the ice cream bars, and the loading of sticks from bulks is also automatic. Included is a separate main drive, PLC control, main magazine for bulk cartons and a reserve stick magazine. 06 Filling equipment for two-coloured ice cream, vertically divided in a zebra-pattern. 19 Tetra Pak Pump Station. 100 litres (26.5 gal.) chocolate floor tank with electrically heated and thermostatically controlled water jacket and electrically driven chocolate circulation pump. The floor tank is a separate unit on wheels and with hoses for connection to the dipping cup on the Tetra Pak Rotary Moulder 35 A2. 07 Filling equipment for two-coloured ice cream, concentric filling. 20 Rack for the storage of mould segments, galvanised or stainless steel 08 Filling equipment for the filling of two-coloured ice cream, horizontally divided. 24 Extended set of spare parts for two years operation. 09 Independent filling unit for one-coloured water ice (required for water ice). 26 Communication set with a central computer. 05 Filling equipment for two-coloured ice cream, vertically divided. 10 Filling equipment for shell and core split ice: shell of water ice, core of ice cream. 11 Equipment for one-coloured water ice, but two different colours per radial row. (Three and four colours per radial row is also available.) 12 Filling equipment for two-coloured water ice, vertically divided (twin-type lolly only). 25 External plate heat exchanger for brine chilling. 28 Mould table with alternative pocket and row configurations. The number of freezing pockets which can be fitted into a Tetra Pak Rotary Moulder 35 A2 mould table depends on the size and shape of the ice cream stick novelty. Between 12 and 28 freezing pockets per radial row is possible. The number of radial rows will depend on the thickness of the product (see tables under Capacity). Other optional equipment is available and full details can be obtained on request.
Product examples The numbers in the table below refer to the list of optional equipment in the previous page. Standard equipment required Optional equipment required A One-coloured water ice, two different colours per radial row 11 B Two-coloured water ice vertically divided (twin type) 12 C Pencil filled ice cream 01 + 13 D Chocolate coated bars 02 01 + 19 E Dry coated ice cream 02 01 + 15 + 19 F One-coloured ice cream 01 or 16 G Bottom filled one-coloured ice cream 04 or 17 H Two-coloured ice cream vertically divided 05 or 16 I Two-coloured ice cream vertically divided zebra pattern 05 + 06 J Two-coloured ice cream concentric 05 + 07 or 16 K Two-coloured ice cream horizontally divided 05 + 08 or 16 L One-coloured water ice 09 or 16 M Two-coloured water ice horizontally divided 09 + 09 N Three-coloured water ice horizontally divided 09 + 09 + 09 O Split ice 09 + 10 + 01 or 16 A B C D E F G H I J K L M N O
Tetra Pak Rotary Moulder 35 A2 Moulded stick novelty freezer Technical data Electric motors Mould table servo index drive 3.9 kw (5.2 HP) Servo choco dip 1.8 kw (2.4 HP) Brine quantity 6 000 litres/7 700 kgs (1 585 gall./17 000 lbs) Lay-down servo 1.8 kw(2.4 HP) Ammonia quantity Extractor index servo 3.9 kw(5.2 HP) For filling the evaporator Cold brine pump 700 litres/458 kg (185 gall./1 070 lbs) 7.5 kw(10 HP) Booster pump to PHE 7.5 kw(10 HP) Air consumption Warm brine pump 1.5 kw (2.0 HP) Standard machine Chocolate drip tray 0.8 kw (1.1 HP) Min. working pressure Dry coating equipment 1.1 kw (1.5 HP) Max. dew point at atmospheric pressure corresponding to Vacuum pump 2.2 kw (3 HP) Juice return pump 0.55 kw (0.75 HP) Heating elements Warm brine, heated either by electricity or by steam. The choice must be made when ordering. Installed max. effect 0.9 m³/min (32 ft3/min) 7 bars (102 psi) +5 C (+41 F) Normal working temperatures Evaporating temperature 45 C ( 49 F) Temp. of cold brine 40 C ( 40 F) Temp. of warm brine +20 C (+77 F) Refrigeration load Electricity Standard connection 3 x 400 Volts, 50 Hz AC Nominal load 180 Amps Main circuit breaker 250 Amps Max. evaporator capacity up to 325 kw/279,000 kcal/h (93.2 TR) at 45 C ( 49 F) Weight in ready-to-work condition, approx. - when thawing by means of steam 20 kw - when thawing by means of electricity 101 kw Low pressure steam 100 kg (220 lbs)/h Consumption of max. effect when in production 55-75% 100 litre chocolate container (Tetra Pak Pump Station) 24 000 kg (52 900 lbs) Shipping data Net weight 16 350 kg (36 000 lbs) Gross weight 20 500 kg (45 200 lbs) Volume 100 m³ (3 530 ft3) 3 kw Main dimensions Total height Cable for main power according to local regulations Height of table above floor Normally required floor-to-ceiling height Pipe connections NH3 liquid line, pump recirculation NH3 suction line Cold brine pipe size to / from PHE Main inlet for air 89.9 mm (3 ½ ) 219 mm (8 3/5 ) 100 mm (3,9 ) 20 mm (¾ ) Piping dimensions for ice cream not less than the outlet of the continuous freezer. 2 800 mm (110 ) 1 500 mm (57 ) 3 000 mm (118 )
Typical layout Tetra Pak Rotary Moulder 35 A2 Tetra Pak Multilane Wrapper Measurements in mm Brine pipes not supplied by Tetra Pak Dimensions Measurements in mm
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